Composite Roof Attachment Bracket Design
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Solution Overview
Problem
The existing methods for attaching a composite roof to a vehicle body structure result in an undesirable gap that requires additional components like roof ditch moldings to cover, leading to quality and appearance concerns due to tolerance issues and the need for multiple parts to achieve a smooth exterior surface.
Innovation Solution
A roof attachment system using a C-section or similarly shaped mounting bracket that is bonded to both the roof panel and the vehicle body structure with adhesive, reducing the gap between them and eliminating the need for roof ditch moldings by using an edge trim to close the remaining gap, thereby maintaining a consistent and aesthetically pleasing Class A surface appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional adhesive and mechanical fastener attachment methods are used with an attaching flange, then the roof can be securely attached to the vehicle body structure, but it creates an undesirable gap and depression that requires additional roof ditch moldings to cover
Solution Approach 1:
A mounting bracket is introduced as an intermediary component between the roof panel and the vehicle body structure. This bracket is shaped to match the interior surface of the Class A roof attachment portion and creates a C-section or predetermined cross-section that fills the gap space, eliminating the need for separate roof ditch moldings while maintaining secure attachment through adhesive bonding
Solution Approach 2:
The mounting bracket combines multiple functions into a single component: it provides structural attachment support, fills the gap between roof and body structure, and creates a smooth transition surface. This merging eliminates the need for separate roof ditch moldings and reduces the total number of parts required
2Shape
If multiple components including roof ditch moldings are used to cover the gap, then the exterior surface appearance can be improved, but the device complexity and number of parts increase
Solution Approach 1:
The mounting bracket combines multiple functions into a single component: it provides structural attachment support, fills the gap between roof and body structure, and creates a smooth transition surface. This merging eliminates the need for separate roof ditch moldings and reduces the total number of parts required
Solution Approach 2:
The invention extracts and eliminates the separate roof ditch molding component from the traditional assembly. By redesigning the mounting bracket to perform the gap-filling function, the unnecessary second component is removed, simplifying the overall device
3Strength
If traditional attaching flange construction is used, then mechanical fastening is achieved, but it creates a depression and flat flange that requires additional molding to achieve desired exterior appearance
Solution Approach 1:
A mounting bracket is introduced as an intermediary component between the roof panel and the vehicle body structure. This bracket is shaped to match the interior surface of the Class A roof attachment portion and creates a C-section or predetermined cross-section that fills the gap space, eliminating the need for separate roof ditch moldings while maintaining secure attachment through adhesive bonding
Solution Approach 2:
The invention replaces traditional mechanical fastening with an attaching flange and roof ditch molding assembly with a simplified adhesive bonding system using the shaped mounting bracket. The bracket's geometry provides the necessary structural support and gap filling without requiring separate mechanical fasteners or additional moldings
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
The solution achieves a tighter fit and reduced gap between the composite roof and the vehicle body, enhancing the appearance and eliminating the need for additional moldings, while accommodating variable offsets and mass requirements, thus improving the overall design and quality of the vehicle surface.
Implementation Method 1
The mounting bracket is bonded to the roof panel with adhesive and bonded to the body structure with adhesive
Implementation Method 2
An edge trim closes off the gap therebetween and is held in place by adhesive and/or frictional engagement
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A roof attachment system and method for connecting a composite molded roof to a vehicle body structure, having a plurality of mounting members that each create a C- like section part that is shaped to match the inside surface of the composite Class A roof. The mounting member is bonded to the roof panel with adhesive. The roof is aligned with key features to locate the roof within an opening, where the mounting member is then also bonded to the body structure with adhesive.