Rear Roof Crossmember Bracket With Integrated Grab Handle Support
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Solution Overview
Problem
The existing motor vehicle structures with sunroofs are weakened and require complex, bulky gussets and grab handle supports, making them difficult to manufacture and assemble effectively.
Innovation Solution
A motor vehicle structure with simplified gussets and grab handle supports, where the grab handle support is integrated into the gusset with vertically or inclined anchoring orifices, and electrical resistance welding points are used for secure attachment between the gussets, lateral supports, and rear roof crossmember, optimizing the gusset shape and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rear crossmember with gusset and grab handle support is added to the vehicle structure, then the structural strength is improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent combines the gusset and grab handle support into a single integrated component. The gusset serves dual functions: reinforcing the roof structure and providing mounting support for the grab handle. This merging eliminates the need for separate components, reducing assembly steps and overall structural complexity while maintaining both structural strength and handle support functionality.
Solution Approach 2:
The gusset is designed as a multi-functional element that simultaneously provides structural reinforcement and serves as a mounting bracket for the grab handle. By making the gusset universal in its functionality, the patent reduces the total number of parts required and simplifies the overall assembly process while achieving both structural and functional requirements.
2Stability of the object's composition
If the grab handle support is offset towards the rear of the crossmember, then the structural distribution is improved, but the manufacturing complexity and bulkiness increase
Solution Approach 1:
The grab handle support is merged with the gusset into a single stamped component. The anchor holes for the handle are formed directly in the gusset material, eliminating the need for separate mounting brackets or complex offset structures. This integration maintains proper structural distribution while dramatically simplifying manufacturing to a single stamping operation.
Solution Approach 2:
The patent changes the geometric parameters of the gusset by forming anchor holes directly in the stamped material rather than requiring separate offset mounting structures. This parameter change in the design approach transforms a complex multi-component assembly into a simple single-piece component with optimized hole placement that achieves both structural distribution and ease of manufacture.
3Adaptability or versatility
If multiple separate components are used for gusset and handle support, then the assembly flexibility is improved, but the assembly time and productivity decrease
Solution Approach 1:
The gusset and grab handle support are merged into a single integrated component that is installed as one unit. This eliminates multiple assembly steps involving separate components and fasteners, reducing assembly time significantly. The integrated design maintains all necessary mounting points and structural features while requiring only a single installation operation, thereby improving productivity without sacrificing assembly flexibility.
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
This solution simplifies the manufacturing and assembly of gussets, enhances the structural rigidity, and ensures efficient and stable attachment to the roof arches, improving the overall structural integrity of the vehicle.
Implementation Method 1
electrical resistance welding points are used for secure attachment between the gussets, lateral supports, and rear roof crossmember
Data Source
Figure 1~2
AI summary
The invention relates to a structure of a motor vehicle with sunroof (3A), said structure having, on each of the two lateral sides (5), an arch (7) of the rear roof panel (3) with a lining (7B); a rear cross member (11) of the roof panel (3) extending transversely between the two arches (7) of the rear roof panel (3) and comprising two ends (11A); a bracket (15) connecting each of the ends (11A) to the corresponding lining (7B); and, at at least one of the two lateral sides (5), a grab handle support; the at least one grab handle support being formed directly on the corresponding bracket (15) and comprising two anchoring holes (17D) of said handle, said anchoring holes (17D) being perpendicular to the rear crossmember (11) of the roof panel (3).