Roof Side Member and Outer Panel Load Path for Modular Vehicle Bodies

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Solution Overview

Problem

Existing vehicle frame structures require numerous components and are not adaptable to small quantity batch production, limiting competitiveness in future mobility markets.

Innovation Solution

A vehicle frame design incorporating a hollow pipe member with integrated flanges and an outer panel that supports and distributes load, reducing the number of components and allowing for configuration variations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If panel types are used for A, B, and C pillars and coupled by welding, then mass production is advantageous, but the number of components and apparatus increases

Engineering Contradiction:

Improvemass production efficiencyVSAvoidnumber of components

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent combines multiple separate components (pillars and panels) into an integrated body-in-white structure where the outer panel is continuously coupled to multiple pillars, reducing the number of discrete components and welding joints required in traditional assembly methods

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The outer panel serves multiple functions simultaneously: it provides structural support, forms the vehicle exterior surface, and creates load paths between pillars, eliminating the need for separate structural and cosmetic components

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of manufacture

If many apparatus such as mold are required for assembly, then welding coupling is achieved, but adaptability to small quantity batch production decreases

Engineering Contradiction:

Improvewelding coupling capabilityVSAvoidadaptability to small quantity batch production

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The body-in-white structure is designed as modular segments that can be independently manufactured and then assembled, allowing flexible production quantities without requiring complete retooling for different vehicle types

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The continuous outer panel design allows for dynamic adaptation to different vehicle configurations without requiring fixed mold setups, enabling small batch production of various vehicle types using the same basic structure

Inventive Principle:

Principle #15Dynamics

3Shape

If the whole body in body-in-white state is assembled and undergoes painting process, then exterior appearance is formed, but component count increases

Engineering Contradiction:

Improveexterior appearanceVSAvoidcomponent count

Core Design Contradiction:

ShapeVSDevice complexity

Solution Approach 1:

The outer panel is designed to serve dual purposes: it provides the exterior appearance surface and simultaneously acts as a structural load-bearing component, merging cosmetic and structural functions into a single element that reduces overall component count

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS12509158B2Vehicle body

Publication Date: 2025.12.30 HYUNDAI MOTOR CO LTD

AI summary

A vehicle body includes: a roof side member including a hollow pipe member and a flange. In particular, a vehicle-frame-side inner end portion of the flange is fixed to a roof rail, and a lower end portion of the flange extends downward from the pipe member and is fixed to a pillar member. The vehicle body further includes an outer panel combined with the outside of the roof side member and forming a load path between the roof side member and the pillar member by coupling a lower end portion of the roof side member and an upper end portion of the pillar member to each other.