Vehicle Sunroof Mounting Frame with Metal Insert Plate
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Solution Overview
Problem
Conventional panorama sunroof structures face issues with the heavy front stationary glass member causing wind noise, sagging of the mounting frame, increased vehicle weight, reduced fuel efficiency, and durability problems due to the weight and material limitations of the mounting frame.
Innovation Solution
A sunroof structure that replaces the front stationary glass member with a metal insert plate integrated into a plastic or metal mounting frame, featuring support ribs, through-holes, and weld bolts to enhance structural support and reduce weight, while maintaining a unified external appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a heavy front stationary glass member is used, then the mounting frame can be supported, but the vehicle weight increases and fuel efficiency decreases
Solution Approach 1:
The patent removes the heavy front stationary glass member from the sunroof structure. Instead, it uses a lightweight insert plate made of metal or plastic material that is integrated into the mounting frame, eliminating the need for the separate heavy glass component while maintaining structural support through the frame's support ribs.
Solution Approach 2:
The patent employs composite material construction by integrating the insert plate with the mounting frame through support ribs and fastening mechanisms. The insert plate can be made of metal or plastic, creating a composite structure that provides both strength and weight reduction compared to traditional heavy glass construction.
2Weight of moving object
If a plastic mounting frame is used, then weight is reduced, but the frame sags and causes wind noise or glass breakage
Solution Approach 1:
The mounting frame is divided into multiple segments with support ribs that protrude vertically to provide localized structural support. These ribs are integrally formed with the frame and positioned to prevent sagging while maintaining the overall lightweight plastic construction of the frame.
Solution Approach 2:
The patent creates a composite structure by integrating the insert plate with the plastic mounting frame through support ribs and fastening mechanisms. This composite construction provides enhanced structural integrity to the plastic frame, preventing sagging and deformation while maintaining weight reduction benefits.
3Strength
If a steel mounting frame is used, then structural strength is improved, but the sunroof structure weight increases excessively
Solution Approach 1:
The mounting frame incorporates multiple support ribs that are integrally formed with the frame structure. These ribs are strategically positioned to provide localized reinforcement and torsion strength throughout the frame, eliminating the need for a completely steel construction while maintaining adequate structural strength.
Solution Approach 2:
The patent applies local reinforcement through support ribs and integrated fastening structures at specific locations where strength is needed, rather than using a uniformly heavy steel construction throughout. This allows the frame to have adequate torsion strength where required while maintaining lightweight plastic construction in other areas.
4Strength
If a front stationary glass member is separately fixed to the mounting frame, then the mounting frame can be supported, but assembly complexity increases
Solution Approach 1:
The insert plate is integrally formed with the mounting frame through support ribs and fastening mechanisms, creating a unified structure. This integration eliminates the need for separate attachment of a front stationary glass member, simplifying the assembly process while maintaining structural support functionality.
Data Source
AI summary
A sunroof structure for a vehicle may include a mounting frame made of plastic material, and an insert plate inserted into a front upper side of the mounting frame, forming an upper exposed surface of the vehicle.