Vehicle Roof Structure Three-Surface Joint Gap Reduction
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Solution Overview
Problem
The existing roof structure of vehicles has a complex mold structure that limits design freedom and results in a significant gap between the roof panel and the roof side outer panel, complicating the press-molding process.
Innovation Solution
A roof structure with integrally formed three-surface combination portions on the roof side outer panel, including a roof joint surface, up-down direction joint surface, and front-back direction joint surface, which are continuously formed to reduce the gap between panels and simplify the press-molding process, while also increasing rigidity and allowing for easier assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If a raised portion is formed on the opening frame panel side to reduce the gap, then the gap filling amount is reduced, but the mold structure becomes complicated and design freedom is reduced
Solution Approach 1:
Instead of forming a raised portion on the opening frame panel (as in prior art), the invention inverts the approach by forming a recessed portion on the roof side outer panel. This reversal simplifies the mold structure while achieving the same gap reduction effect, as the recessed portion can be more easily formed during press-molding without requiring complex mold mechanisms.
Solution Approach 2:
The invention changes the geometric parameters of the joint structure by introducing a recessed portion with specific depth and width dimensions. This parameter change allows the gap to be reduced effectively while maintaining a simple mold structure, as the recessed portion can be formed using standard press-molding techniques without requiring additional mold components.
2Manufacturing precision
If the roof joint surface portion is positioned closer to the roof panel to reduce the gap, then the gap is reduced, but the rigidity of the roof side outer panel may be compromised
Solution Approach 1:
The invention addresses the rigidity concern by extending the roof joint surface portion not only in the up-down direction (closer to the roof panel) but also in the front-back direction and left-right direction. This multi-dimensional extension maintains the panel's structural rigidity by distributing stresses across a larger area, while still achieving effective gap reduction through the up-down positioning.
Solution Approach 2:
The roof joint surface portion is segmented into multiple directional extensions (front-back, left-right, and up-down) rather than a single continuous surface. This segmentation allows each portion to independently contribute to both gap reduction and rigidity maintenance, as the distributed structure can better resist various方向的 loads while keeping the overall gap small.
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
The solution effectively reduces the gap between the roof panel and the roof side outer panel, simplifies the press-molding mold, enhances the degree of design freedom, and increases the structural rigidity of the roof structure, allowing for better load distribution and weight reduction.
Implementation Method 1
a laser is irradiated from the outer side of a vehicle body in a state that an inclined surface, obtained in a way that left and right side edges of a roof panel are bent downward and inward in a vehicle width direction, is abutted against the same inclined surface of a side panel (hereinafter, referred to as a roof side outer panel), and base materials are melted and continuously bonded
Data Source
AI summary
Provide is a roof structure of a vehicle, in which, a roof side outer panel, a roof panel, and a rear garter panel are joined. The roof side outer panel has: a roof joint surface portion, an up-down direction joint surface portion, and a front-back direction joint surface portion. The roof panel is joined to the roof joint surface portion in a state of being abutted against the roof joint surface portion. The up-down direction joint surface portion is formed at a lower end of the roof joint surface portion, and the rear garter panel is joined to the up-down direction joint surface portion. The front-back direction joint surface portion is formed at back ends of the up-down direction joint surface portion and the roof joint surface portion in a vehicle body front-back direction, and is joined to the rear garter panel.