Clam Shell Bracket for Automotive Roof Joint
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Solution Overview
Problem
Existing automotive body structure designs fail to effectively connect transversely extending roof cross members to hydroformed tubular side rails using spot-welding, resulting in weak joints and increased manufacturing costs due to notching requirements.
Innovation Solution
A two-piece clam shell bracket configuration that secures a transverse roof cross component to a tubular roof side rail, with a lower piece welded to the underside of the rail and projecting to receive the cross member, and an upper piece clamping over the cross member and rail, providing reinforcement without additional processing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a transverse roof cross member is connected to a hydroformed tubular side rail using conventional spot-welding, then the welding process can be simplified, but the joint strength is insufficient and the body structure integrity is compromised
Solution Approach 1:
A bracket is introduced as an intermediary component between the transverse roof cross member and the hydroformed tubular side rail. The bracket provides a mounting flange with accessible surfaces for spot-welding, while its configuration member engages with the cross member to create a strong joint. This mediator resolves the contradiction by enabling strong connections without requiring direct welding between the tubular members.
Solution Approach 2:
The connection system is divided into separate components: the bracket with a mounting flange for attachment to the side rail, and a configuration member for engagement with the cross member. This segmentation allows each component to be optimized for its specific function, with the bracket providing welding accessibility and the configuration member providing structural engagement, thereby achieving both strong joints and manufacturing ease.
2Ease of manufacture
If the body structure members are positioned in a parallel orientation for spot-welding, then the welding process becomes feasible, but the structural design flexibility is reduced and additional notching is required
Solution Approach 1:
The bracket serves as a mediator that eliminates the need for parallel positioning and notching of the tubular members. The mounting flange of the bracket provides accessible surfaces for spot-welding to the side rail, while the configuration member engages with the cross member in a manner that accommodates various structural designs without requiring modifications to the tubular members themselves.
3Strength
If a mounting bracket is used to connect separate roof rail components, then the joint strength is improved, but notching is required which increases manufacturing expense and weakens the roof side rail
Solution Approach 1:
The bracket is designed as an intermediary component that achieves strong joints without requiring notching of the roof side rail. The mounting flange attaches to the exterior surface of the side rail through spot-welding, while the configuration member engages with the cross member, thereby providing structural reinforcement without compromising the integrity of the rail or incurring additional manufacturing costs.
4Strength
If the two body structure members are sized to snuggly fit together before spot-welding, then the joint strength is improved, but the adaptability to different sized members is reduced
Solution Approach 1:
The bracket is designed as a universal connecting component that can accommodate body structure members of different sizes. The mounting flange can be attached to side rails of varying dimensions, and the configuration member can engage with cross members of different configurations. This multi-functionality enables strong joints across various member sizes without requiring custom-fitted connections.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enhances joint strength and body structure integrity without notching the roof side rail, while being cost-effective and simple to assemble, using either welding or adhesives for securement.
Implementation Method 1
A lower piece formed in a shape to mate to and receive the transverse roof cross member is welded to the underside of the tubular roof side rail
Implementation Method 2
An upper piece clamps over top of the transverse roof cross member and is welded to the top portion of the tubular roof side rail
Implementation Method 3
The joint apparatus can be secured to the transverse roof cross member and to the roof side rail by either welding or by adhesives
Data Source
AI summary
A structural joint configuration is used in an automotive body structure in which a transverse roof cross member has a convoluted formed shape that must be connected to the longitudinally extending tubular roof side rail. A two-piece clam shell bracket forms the joint apparatus. A lower piece formed in a shape to mate to and receive the transverse roof cross member is welded to the underside of the tubular roof side rail while projecting a formed receiver to engage the transverse roof cross member. An upper piece clamps over top of the transverse roof cross member and is welded to the top portion of the tubular roof side rail. The joint apparatus can be secured to the transverse roof cross member and to the roof side rail by either welding or by adhesives to provide a reinforcement at the joint between the two structural members.