Vehicle Body Roof-Side Joint Structure for Torsional Rigidity
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Solution Overview
Problem
Current vehicle body structures face challenges in achieving high robustness, strength, and torsional rigidity while maintaining a low weight, which is essential for improved crash safety and drivability.
Innovation Solution
A vehicle body structure comprising a roof structure with a roof panel fastened to an underlying reinforcement frame via a hemming joint and connected to a lateral side structure using an elongated laser brazing joint, allowing for enhanced force transfer and increased stiffness without significant weight increase, along with a simplified manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional joining methods are used to connect roof panel to side panel, then manufacturing simplicity is maintained, but the strength and torsional rigidity of the vehicle body structure is insufficient
Solution Approach 1:
The patent replaces traditional mechanical joining methods (such as spot welding or mechanical fasteners) with laser brazing technology. The laser brazing joint creates a continuous metallurgical bond between the roof panel and side panel, significantly enhancing the strength and torsional rigidity of the vehicle body structure while maintaining manufacturing efficiency through automated laser processing.
Solution Approach 2:
The patent employs a composite joining approach combining hemming (mechanical deformation) and laser brazing (metallurgical bonding). The hemmed edge of the roof panel provides mechanical interlocking with the side panel, while the laser brazing adds a metallurgical bond, creating a hybrid joint that leverages both mechanical and thermal bonding mechanisms to achieve superior strength.
2Strength
If heavier materials or thicker panels are used to increase robustness, then strength and crash safety are improved, but vehicle weight increases
Solution Approach 1:
The patent changes the joining parameters and methodology rather than modifying the base materials. By transitioning from discrete mechanical fasteners or spot welds to continuous laser brazing, the joint strength and structural rigidity are enhanced without requiring thicker panels or heavier materials, thus maintaining vehicle weight efficiency while improving crash safety.
3Productivity
If multiple separate joining operations are used to connect roof and side structures, then adaptability is maintained, but manufacturing time and productivity are reduced
Solution Approach 1:
The patent merges the hemming operation and the joining operation into a integrated process sequence. The roof panel is first hemmed along its edge to create an interlocking profile, then the laser brazing is applied in a continuous operation to metallurgically bond the hemmed edge to the side panel. This combined approach eliminates the need for separate mechanical fastening operations, significantly improving manufacturing efficiency.
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 configuration enhances the overall stiffness and crash safety of the vehicle body, reduces noise and vibration, and provides increased passenger compartment space while maintaining a lightweight design.
Implementation Method 1
fastening the folded edge of the roof panel to the side panel by means of an elongated laser brazing joint
Implementation Method 2
elongated laser brazing joint
Implementation Method 3
folding a lateral side of the roof panel around an edge of the roof reinforcement frame to fasten the lateral side of the roof panel to the roof reinforcement frame by means of a hemming joint
Data Source
AI summary
A vehicle body structure includes a roof structure and a lateral side structure, wherein the roof structure includes a roof panel fastened to an underlying roof reinforcement frame, wherein the lateral side structure includes a side panel fastened to an underlying side support structure, wherein a lateral side of the roof panel is fastened to the roof reinforcement frame by means of a hemming joint that is formed by folding a lateral side of the roof panel around an edge of the roof reinforcement frame, and wherein a folded side edge of the roof panel is fastened to the side panel by means of an elongated laser brazing joint.