Roof Rail Bulkhead Structure for Rollover Load Transfer
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Solution Overview
Problem
Conventional methods to improve load force transfer from a vehicle's roof rail to the B pillar, such as welding or modifying reinforcement panel gauge, result in increased vehicle mass and production costs, and fail to effectively distribute load forces during a rollover event.
Innovation Solution
A load force transfer member is strategically positioned to connect the roof rail to the B pillar, allowing early interaction and distributing load forces without altering panel gauge or material specifications, thereby enhancing load force transfer capability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding the B pillar to the roof rail at a junction is used to improve joint strength and load force transfer capability, then the load force transfer capability is improved, but the vehicle mass and production cost increase
Solution Approach 1:
A load force transfer member is introduced as an intermediary component between the roof rail and the B pillar. This member includes a first portion connected to the B pillar and a second portion that contacts the roof rail during a roof impact event, enabling load force transfer without direct welding between the B pillar and roof rail, thereby avoiding the need for additional reinforcement that would increase vehicle mass.
Solution Approach 2:
The load force transfer member is divided into distinct portions: a first portion connected to the B pillar and a second portion that contacts the roof rail. This segmentation allows the load force transfer function to be separated from the main structural components, enabling the use of lighter materials or configurations in the overall vehicle structure while maintaining the required strength at the load transfer interface.
2Strength
If welding the B pillar to the roof rail at a junction is used to improve joint strength and load force transfer capability, then the load force transfer capability is improved, but the production cost increases
Solution Approach 1:
The load force transfer member serves as a mediator that simplifies the manufacturing process by eliminating the need for complex welding operations between the B pillar and roof rail. The member can be separately manufactured and then attached to the B pillar, allowing for more straightforward production and potential use of cost-effective materials or attachment methods.
Solution Approach 2:
The load force transfer member may be designed as a simpler, potentially less expensive component that can be manufactured using cost-effective processes. By using this dedicated load transfer member instead of relying on expensive reinforcement panels or complex welding procedures, the overall production cost is reduced while maintaining the required safety performance.
3Strength
If modifying reinforcement panel gauge and panel material specifications is used to improve load force transfer, then the load force transfer capability is improved, but the vehicle mass and production cost increase
Solution Approach 1:
The load force transfer member acts as a specialized intermediary component that provides the necessary load force transfer capability without requiring the entire reinforcement panel to be made of heavier, stronger materials. This localized approach allows the use of lighter materials for the bulk of the vehicle structure while concentrating strength where it is most needed for load transfer.
Solution Approach 2:
The load force transfer member provides localized strength and load transfer capability at the specific location where it is needed (between the roof rail and B pillar). This allows other parts of the vehicle structure to use lighter materials, reducing overall vehicle mass while maintaining the required load force transfer capability at the critical interface.
Data Source
AI summary
A vehicle roof support structure on a vehicle. The vehicle roof support structure includes a roof rail member extending in a lengthwise direction of the vehicle. The vehicle roof support structure also includes a side pillar member disposed at least partially below the roof rail member on a lateral side of the vehicle and extending substantially in a vertical direction of the vehicle. The vehicle roof support structure further includes a load force transfer member. The load force transfer member includes a first portion connected to the side pillar member and a second portion spaced a predetermined distance away from a closest point on the roof rail member. The load force transfer member is configured to assume at least a portion of a load force applied on the roof rail member during a roof impact event.