Vehicle Roof Bow Insert Block for Side Impact Strength
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Solution Overview
Problem
Current methods to enhance side impact strength in vehicle roofs often increase weight and manufacturing costs by thickening roof rails, which can compromise visibility and structural efficiency.
Innovation Solution
A vehicle roof structure assembly that includes a mounting bracket, a roof bow with an inner channel, an insert block, and dimples on the roof bow's exterior surface to secure the insert block within the channel, using fasteners to rigidly connect these components and distribute impact loads effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the section size and thickness of roof rails are increased to improve side impact strength, then side impact resistance is improved, but vehicle weight increases and manufacturing costs increase
Solution Approach 1:
The patent employs composite construction by integrating multiple materials and structures: the insert block (potentially different material properties) within the roof bow cavity, the roof bow itself with optimized cross-section, and the mounting bracket system. This composite approach allows achieving high side impact strength without uniformly increasing the thickness of all roof rail components, thereby avoiding excessive weight gain.
Solution Approach 2:
The reinforcement system is segmented into distinct functional components: the insert block placed within the roof bow cavity, the roof bow structure itself, and the separate mounting bracket assembly. This segmentation allows each component to be optimized independently for its specific function while collectively providing enhanced side impact resistance without requiring a uniform increase in overall roof rail thickness.
2Strength
If the section size and thickness of roof rails are increased to improve side impact strength, then side impact resistance is improved, but manufacturing costs increase
Solution Approach 1:
The reinforcement system is divided into separable components (insert block, roof bow, mounting bracket) that can be manufactured independently using optimized processes for each part, then assembled together. This segmentation allows each component to be produced efficiently at standard thicknesses while achieving overall high strength through their combined configuration, reducing total manufacturing cost compared to producing a single thickened roof rail.
Solution Approach 2:
By using a composite assembly of multiple components with potentially different material properties and thicknesses, the system achieves high side impact strength without requiring all components to be manufactured at high cost. The composite structure allows optimization of each component's manufacturing process independently.
3Strength
If the thickness of roof rails is increased to improve side impact strength, then side impact resistance is improved, but visibility below the roof rail is reduced
Solution Approach 1:
The reinforcement function is segmented and relocated to internal components (insert block within the roof bow cavity and mounting bracket system) rather than increasing the external dimensions of the roof rail. This segmentation allows the visible portion of the roof rail to maintain its original thickness and profile, preserving visibility, while the hidden internal components provide the necessary structural reinforcement for side impact resistance.
Data Source
AI summary
A vehicle roof structure assembly includes a mounting bracket having a first aperture disposed therethrough. The vehicle roof structure assembly further includes a roof bow having a longitudinal body portion defining an inner channel. The longitudinal body portion includes a bottom wall having a second aperture axially aligned with the first aperture. The vehicle roof structure assembly further includes an insert block disposed within the inner channel of the roof bow. The insert block defines a third aperture disposed through a thickness of the insert block. The third aperture is axially aligned with the first aperture and the second aperture. The vehicle roof structure assembly further includes a fastener disposed through the first aperture, the second aperture, and the third aperture to rigidly secure the roof bow to the mounting bracket, and to rigidly secure the insert block to the roof bow.