Roof Panel Reinforcement via Segmented Bow Structure

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Solution Overview

Problem

Vehicles with moonroofs or sunroofs often lack the B-Pillar roof bow, which compromises roof strength and side impact intrusion resistance, necessitating additional support to meet strength requirements.

Innovation Solution

The integration of a lower and upper roof bow structure, formed from sheets with transverse mating surfaces and channel walls, creates a hollow channel to enhance torsion resistance and roof crush strength, with the upper roof bow being secured to the lower roof bow to form a continuous support system.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the B-Pillar roof bow is omitted to accommodate moonroof or sunroof assemblies, then the vehicle can have moonroofs or sunroofs, but the roof strength and side impact intrusion resistance are compromised

Engineering Contradiction:

Improvemoonroof assembly installationVSAvoidroof crush strength

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The roof bow is divided into an upper portion and a lower portion that are separately formed and then joined together. The lower roof bow portion is attached to the vehicle body while the upper roof bow portion is attached to the moonroof housing, creating a segmented structure that maintains strength without compromising moonroof installation

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The upper roof bow portion is nested within the moonroof housing structure, with the moonroof housing serving as the outer shell and the upper roof bow portion integrated within it. This nesting allows the roof bow function to be incorporated into the moonroof assembly itself

Inventive Principle:

Principle #7Nested doll (Nesting)

2Adaptability or versatility

If the B-Pillar roof bow is omitted to accommodate moonroof or sunroof assemblies, then the vehicle can have moonroofs or sunroofs, but the torsion resistance is compromised

Engineering Contradiction:

Improvemoonroof assembly installationVSAvoidtorsion resistance

Core Design Contradiction:

Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The roof bow structure combines different materials and construction methods for the upper and lower portions, with each portion optimized for its specific function while working together to provide overall torsion resistance

Inventive Principle:

Principle #40Composite materials

3Strength

If additional support structures are added to compensate for the missing B-Pillar roof bow, then the roof strength requirements can be met, but the device complexity increases

Engineering Contradiction:

Improveroof crush strengthVSAvoidroof support structure

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The upper roof bow portion is merged with the moonroof housing to form an integrated assembly. The moonroof housing serves dual purposes as both the mounting structure for the moonroof glass and as part of the roof bow support structure, eliminating the need for separate support components

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The moonroof housing is designed to serve multiple functions: it houses the moonroof glass, provides mounting points for the upper roof bow portion, and contributes to the overall roof structural strength. This multi-functionality reduces the need for additional dedicated support structures

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS10160501B1Roof panel reinforcement

Publication Date: 2018.12.25 FORD GLOBAL TECH LLC

AI summary

A vehicle includes a lower roof bow and an integrally-formed roof panel. The lower roof bow extends transversely between roof rails and defines a lower channel wall. The integrally-formed roof panel has longitudinal rails and an upper roof bow. The longitudinal rails extend parallel to the roof rails. The upper roof bow is secured to the lower roof bow. The upper roof bow includes an upper channel wall having an interior surface and an exterior surface. The interior surface is spaced from the lower channel wall to define a channel therebetween. The exterior surface defines an exterior surface of the vehicle.