Vehicle Roof Structural Node With Intumescent Foam
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Solution Overview
Problem
The assembly of carrying means on vehicle roofs often results in localized deformation due to manufacturing tolerances, affecting the perceived quality and integrity of the vehicle body.
Innovation Solution
A structural arrangement using a roof stretcher, body side reinforcement, and structural foam to create a load transfer path, with a fixing reinforcement that includes an inverted U-section profile and a bridge linking the fixing strips, compensating for assembly play through intumescent structural foam expansion during welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If structural parts are assembled by welding with partial overlap to form force transfer nodes, then structural strength is improved, but manufacturing precision deteriorates due to assembly dispersion from tolerances causing localized deformation
Solution Approach 1:
The patent applies preliminary action by pre-assembling the roof stretcher, body side reinforcement, and body side liner into a complete box structure before final assembly to the body. This pre-assembly allows tolerances to be compensated within the sub-assembly rather than propagating to the final assembly, preventing localized deformation while maintaining structural strength through the welded force transfer nodes.
Solution Approach 2:
The patent implements beforehand cushioning by designing the force transfer path with inherent compliance and load distribution characteristics. The stacked structural parts (roof stretcher, reinforcement, liner) create a distributed force transfer mechanism that cushions against assembly dispersion, preventing stress concentration and localized deformation at critical joints.
2Ease of operation
If fixing reinforcement is used to attach carrying means to the body, then ease of operation is improved, but manufacturing precision deteriorates due to visible localized deformation of the roof
Solution Approach 1:
The fixing reinforcement is pre-integrated into the force transfer path structure during sub-assembly fabrication. This preliminary integration ensures that the fixing points are precisely positioned relative to the structural components, allowing easy attachment of carrying means while maintaining roof surface quality by distributing loads through the pre-positioned reinforcement structure rather than creating localized deformation.
3Strength
If multiple structural parts are stacked to form force transfer nodes, then structural strength is improved, but device complexity increases
Solution Approach 1:
The patent merges the roof stretcher, body side reinforcement, and body side liner into an integrated box structure that forms the force transfer path. By combining these components into a unified sub-assembly with integrated welding, the design achieves high force transfer capability while reducing overall assembly complexity, as the pre-assembled box unit is installed as a single module rather than requiring complex field assembly of individual components.
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
This solution ensures a robust and deformation-free assembly of carrying means, enhancing the vehicle's structural integrity and perceived quality by compensating for manufacturing tolerances and assembly dispersion.
Implementation Method 1
compensate for the assembly play present between the body structure and the fixing reinforcement by means of an intumescent structural foam
Data Source
Figure 1~2
Figure 3~5
AI summary
The invention relates to an arrangement of a vehicle body (1), in particular an automobile, comprising a body structure and a roof (2), the body structure including at its apex a roof beam formed by a body side (3) and/or a body side reinforcement (6) and/or a body side lining (7), the stacking of which defines a load transfer channel (12), the body comprising a structural node (10) at the junction of the channel (12) with a cross member support (5) (4), the roof (2) being connected to the body by means of a fastening reinforcement (9), the reinforcement (9) comprising a structural foam (16) enabling the roof (2) to be attached to the structural node (10). The invention also relates to a method of constructing the arrangement and to a vehicle comprising such an arrangement.