Composite Roof Panel Assembly with Center and Auxiliary Rails
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Solution Overview
Problem
The manufacturing processes for vehicles with and without sunroofs differ significantly, leading to variations in vehicle body structures, center of mass, and stiffness, making it difficult to lighten the roof panel without a sunroof and affecting fuel efficiency.
Innovation Solution
A roof panel assembly using lightweight composite materials like Fiber Reinforced Plastic (FRP) or Sheet Molding Compound (SMC), with a center rail and auxiliary rail system, spacers, and side brackets, allowing for a common vehicle body structure regardless of sunroof installation, and improving fuel efficiency by reducing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the roof panel is manufactured using steel material to match the vehicle body material, then the structural strength and stiffness are maintained, but the weight of the roof panel increases, adversely affecting fuel efficiency
Solution Approach 1:
The patent applies composite materials (FRP or SMC) for the roof panel instead of traditional steel. These composite materials provide sufficient structural strength and stiffness while significantly reducing the weight of the roof panel, thereby improving fuel efficiency without compromising structural integrity.
2Reliability
If different vehicle body structures are designed for vehicles with and without sunroofs, then the specific structural requirements are met, but the manufacturing processes become different and the complexity of the vehicle platform increases
Solution Approach 1:
The patent designs the vehicle body structure with universal mounting provisions that can accommodate both sunroof and non-sunroof configurations. The roof panel assembly includes standardized mounting points and structural features that work for both vehicle types, allowing a single base platform to serve multiple configurations without requiring fundamentally different body structures.
3Stability of the object's composition
If the roof panel is made heavier to improve structural stiffness, then the vehicle body stiffness is maintained, but the fuel efficiency deteriorates
Solution Approach 1:
The patent uses composite materials (FRP or SMC) that provide high strength-to-weight ratio and sufficient stiffness for the vehicle body structure. These materials maintain the required structural stability and rigidity while being significantly lighter than steel, thereby improving fuel efficiency without sacrificing vehicle body stiffness.
Data Source
AI summary
A roof panel assembly of a vehicle may include a roof panel made of composite material and assembled in a vehicle roof, and a center rail attached to the bottom surface of the roof panel. Both side end portions of the roof panel is assembled with roof rails of the vehicle. The center rail includes both end portions connected to roof rails of the vehicle, respectively. The roof panel further includes an auxiliary rail attached on the bottom of the roof panel and placed at a location spaced apart from the center rail at a rear side in the fore and aft direction of the vehicle.