Segmented Front Header Structure for Sunroof Integration

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Solution Overview

Problem

Modern vehicle designs face challenges in creating a front header structure that is both lightweight and strong enough to meet roof crush requirements while accommodating a top-loaded sunroof, which limits the space available for the front header structure.

Innovation Solution

A front header structure with an elongated shape extending laterally and comprising three parts - a lower part, an upper part, and a rear part - each with a step-like cross-sectional shape, forming compartments that provide strength and absorb impact energy, allowing for a compact, lightweight, and material-saving design that integrates well with a top-loaded sunroof.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the front header structure is made stronger to meet roof crush requirements, then the strength and stiffness are improved, but the weight increases

Engineering Contradiction:

ImprovestrengthVSAvoidweight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The front header structure is divided into three separate parts: a lower part, an upper part, and a rear part. Each part can be independently manufactured and then assembled together, allowing for optimized weight distribution and strength in different sections of the structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent employs composite construction by combining multiple parts (lower part, upper part, rear part) into an integrated front header structure that functions as a unified strong component while maintaining lightweight characteristics through the modular assembly approach.

Inventive Principle:

Principle #40Composite materials

2Adaptability or versatility

If the top-loaded sunroof is installed to provide desired functionality and aesthetic appearance, then the sunroof functionality is improved, but the space for the front header structure is reduced

Engineering Contradiction:

Improvesunroof functionalityVSAvoidspace for front header structure

Core Design Contradiction:

Adaptability or versatilityVSVolume of moving object

Solution Approach 1:

By segmenting the front header structure into three parts, the design accommodates the sunroof opening in the upper part while maintaining sufficient structural space and strength in the lower and rear parts that are not compromised by the sunroof installation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The structure applies different design qualities to different parts: the upper part is designed to accommodate the sunroof opening with appropriate structural integrity, while the lower and rear parts are optimized for strength and stiffness without the sunroof constraint, allowing each section to have locally optimized properties.

Inventive Principle:

Principle #3Local quality

3Weight of moving object

If the front header structure is made lightweight to reduce vehicle weight, then the weight is reduced, but the strength and stiffness are compromised

Engineering Contradiction:

ImproveweightVSAvoidstrength

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The segmented three-part design allows each component to be optimized for its specific functional requirements while contributing to the overall lightweight structure, rather than requiring a uniformly heavy construction throughout.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The composite assembly of multiple parts creates a lightweight structure that achieves high overall strength through the synergistic combination of components, each contributing their strength characteristics to the unified structure.

Inventive Principle:

Principle #40Composite materials

4Volume of moving object

If the front header structure is made compact to accommodate the sunroof, then the space utilization is improved, but the structural integrity is reduced

Engineering Contradiction:

Improvespace utilizationVSAvoidstructural integrity

Core Design Contradiction:

Volume of moving objectVSStrength

Solution Approach 1:

The three-part segmented structure achieves compactness by strategically positioning and sizing each component to fit within the available space while maintaining structural integrity through the interconnected assembly of parts.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The composite construction of multiple parts creates a compact yet structurally sound assembly where the combined strength of the lower part, upper part, and rear part provides sufficient structural integrity despite the reduced overall volume required for sunroof accommodation.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS11207951B2Front header structure and a vehicle comprising a front header structure

Publication Date: 2021.12.28 NINGBO GEELY AUTOMOBILE RES & DEV CO LTD

AI summary

A front header structure of a vehicle body has an elongated shape in a lateral direction of the vehicle body and is attached to side structures of the vehicle body. In a longitudinal direction, the front header structure is arranged between a front section of a sunroof opening and an upper section of a windshield opening. The front header structure includes an upper part attached to an lower part and a rear part, where the rear part forms a front frame section of a sunroof frame encompassing the sunroof opening. The lower, upper and rear parts each have a rear lower section, a front upper section and an intermediate step section arranged between the rear lower section and the front upper section. The front header structure includes a first compartment formed between the lower and upper parts and a second compartment formed between the upper and rear parts.