Unitized Vehicle Roof Structure With Integrated Support Braces
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Solution Overview
Problem
Conventional vehicle roof structures are complex due to variations in design (e.g., with or without sunroofs) and require electrical connectivity and support for external structures, complicating manufacturing and assembly.
Innovation Solution
A vehicle roof structure comprising an outer roof panel and a unitized inner roof panel, where the inner panel includes roof headers, a roof bow, and support braces, with the outer panel mechanically interlocked to the inner panel and reinforced by adhesive bonding and reinforcement members, allowing for integrated support of external structures like sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional roof structures use multiple separate parts (roof bows, headers, panels) to accommodate different designs, then adaptability to different roof configurations is improved, but device complexity increases and manufacturing becomes more difficult
Solution Approach 1:
The roof structure is divided into two main segments: an outer roof panel and an inner roof panel assembly. The inner roof panel assembly contains integrated roof bows, headers, and support braces as a unified structure. This segmentation allows the complex inner assembly to be manufactured separately and then mated with the simpler outer panel, reducing overall manufacturing complexity while maintaining adaptability through design variations in the inner assembly.
Solution Approach 2:
The inner roof panel assembly serves multiple functions: it provides structural support through integrated bows and headers, enables different roof configurations (sunroof or fixed), and offers mounting surfaces for external structures. By consolidating these functions into a single universal assembly that can be configured for different applications, the patent reduces the number of separate parts needed while maintaining versatility.
2Adaptability or versatility
If conventional roof structures accommodate different design variations (with or without sunroofs), then adaptability is improved, but manufacturing complexity increases
Solution Approach 1:
The inner roof panel assembly is pre-manufactured with integrated bows, headers, and support braces in a standardized configuration. Design variations such as sunroof or fixed roof are accommodated through pre-planned design options in the inner assembly rather than requiring different manufacturing processes. This preliminary preparation of the inner assembly simplifies manufacturing by using consistent production methods while still allowing for design variations.
Solution Approach 2:
Different roof configurations are achieved by changing parameters of the inner roof panel assembly, such as the presence or absence of sunroof openings, the configuration of support braces, or the integration of reinforcement members. These parameter changes allow a single base manufacturing process to produce multiple roof variations, reducing manufacturing complexity while maintaining adaptability.
3Adaptability or versatility
If roof structures include integrated support for external structures and electrical connectivity, then functionality is improved, but device complexity increases
Solution Approach 1:
The patent combines structural support functions and electrical connectivity functions into the inner roof panel assembly. Reinforcement members are integrated into the inner panel to provide mounting support for external structures like sensors and antennas. Electrical connectivity is built into the inner assembly through integrated wiring harnesses or connection points. By merging these functions into a single integrated assembly rather than adding separate components, the patent reduces overall assembly complexity while enhancing functionality.
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 simplifies manufacturing by reducing parts, enhances structural rigidity, and supports external structures such as sensors, while maintaining electrical connectivity, thus improving assembly efficiency and structural integrity.
Implementation Method 1
an adhesive material is between the outer roof panel and the unitized inner roof panel and bonded to the outer roof panel and the unitized inner roof panel
Data Source
AI summary
A vehicle roof structure of a vehicle includes an outer roof panel and a unitized inner roof panel. The inner roof panel is separate from the outer roof panel and is secured to the outer roof panel. The inner roof panel includes roof headers, a roof bow, and support braces. The roof headers are spaced apart from each other and extend in a transverse direction relative to a longitudinal direction of the vehicle. The roof bow is spaced apart from and positioned between two roof headers of the roof headers and extends in the transverse direction. Each support brace is positioned between the roof bow and one of the two roof headers. The support braces extend from the roof bow to the one of the two roof headers and extend in multiple directions.