U.S. patent application number 15/366817 was filed with the patent office on 2017-03-23 for bowtie shaped roof bow.
The applicant listed for this patent is FORD GLOBAL TECHNOLOGIES, LLC. Invention is credited to Michael M. AZZOUZ, Yijung CHEN, James Chih CHENG, Mohammed Omar FARUQUE, David Anthony WAGNER, Fubang WU.
Application Number | 20170080981 15/366817 |
Document ID | / |
Family ID | 51899973 |
Filed Date | 2017-03-23 |
United States Patent
Application |
20170080981 |
Kind Code |
A1 |
FARUQUE; Mohammed Omar ; et
al. |
March 23, 2017 |
Bowtie Shaped Roof Bow
Abstract
A roof bow for a vehicle is provided that has a "bow-tie" shape
including a central portion flanked by two triangular portions. The
triangular portions are joined to right and left roof brackets that
are, in turn, joined to right and left roof rails. The bow-tie roof
bow may be assembled from extruded tubular parts. The bow-tie roof
bow may be assembled in a clamshell structure including an upper
shell and a lower shell that are joined together by welding. The
roof bow may be formed in one piece as a sheet metal stamping
having side portions that are wider than the central portion.
Inventors: |
FARUQUE; Mohammed Omar; (Ann
Arbor, MI) ; WU; Fubang; (Woodhaven, MI) ;
AZZOUZ; Michael M.; (Livonia, MI) ; CHEN; Yijung;
(Ypsilanti, MI) ; WAGNER; David Anthony;
(Northville, MI) ; CHENG; James Chih; (Troy,
MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
FORD GLOBAL TECHNOLOGIES, LLC |
Dearborn |
MI |
US |
|
|
Family ID: |
51899973 |
Appl. No.: |
15/366817 |
Filed: |
December 1, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14844624 |
Sep 3, 2015 |
9550532 |
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15366817 |
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14049611 |
Oct 9, 2013 |
9156500 |
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14844624 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B62D 25/04 20130101;
B60Y 2410/124 20130101; B62D 25/06 20130101; B62D 21/157 20130101;
B62D 21/15 20130101; B60Y 2306/01 20130101; B62D 27/02 20130101;
B62D 29/008 20130101 |
International
Class: |
B62D 25/06 20060101
B62D025/06; B62D 29/00 20060101 B62D029/00; B62D 27/02 20060101
B62D027/02; B62D 21/15 20060101 B62D021/15 |
Claims
1. A roof bow for a vehicle having a roof comprising: a central
portion having a first width extending transversely across the
roof; a first side portion on a first lateral end of the central
portion; and a second side portion on a second lateral end of the
central portion, wherein the first and second lateral ends have a
second width that is more than twice as wide as the first
width.
2-9. (canceled)
10. The roof bow of claim 1 further comprising: a front step flange
that extends across a front edge of the first side portion, the
central portion, and the second side portion; and a rear step
flange that extends across a rear edge of the first side portion,
the central portion and the second side portion.
11. The roof bow of claim 10 further comprising: a forward rib
extending laterally across the roof bow; and a rearward rib
extending laterally across the roof bow, wherein the forward rib
and the rearward rib diverge outwardly in the first and second side
portions, and wherein the forward rib and rearward rib are parallel
in the central portion.
12. A support structure for a vehicle roof panel comprising: a
right roof rail supporting a right side of the roof panel; a left
roof rail supporting a left side of the roof panel; a roof bow
including a central portion extending transversely across the roof
panel, a first side portion on a first lateral end of the central
portion, and a second side portion on a second lateral end of the
central portion; a right side bracket attached to the right roof
rail and the first side portion; and a left side bracket attached
to the left roof rail and the second side portion.
13. The support structure of claim 12 further comprising a right
B-pillar and a left B-pillar, and wherein the right side bracket
and the left side bracket each extend both in front of and in back
of the B-pillars to a greater extent that the first and second side
portions of the roof bow.
14. The support structure of claim 13 wherein the right B-pillar
and the left B-pillar are laterally aligned with the central
portion.
15. A vehicle body structure for supporting a roof panel
comprising: a roof rail supporting a side of the roof panel; a
B-pillar supporting an intermediate portion of the roof rail; a
bracket attached to the roof rail that extends fore-and-aft of the
B-pillar; and a roof bow having a central portion that extends
transversely across the roof panel, wherein the roof bow has first
and second side portions that extend outwardly from the central
portion in a forward direction and a rearward direction, wherein an
impact force from a side impact collision is transferred to the
bracket, that transfers the impact force to one of the side
portions, and that transfers the impact force to the central
portion of the roof bow.
16-20. (canceled)
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a division of U.S. application Ser. No.
14/844,624 filed Sep. 3, 2015, which is a division of U.S.
application Ser. No. 14/049,611 filed Oct. 9, 2013, now U.S. Pat.
No. 9,156,500 issued Oct. 13, 2015, the disclosures of which are
hereby incorporated in their entirety by reference herein.
TECHNICAL FIELD
[0002] This disclosure relates to the structure of a roof bow for a
vehicle roof that minimizes intrusions into the passenger
compartment in side impact collision tests ad roof crush tests.
BACKGROUND
[0003] Roof bows are attached to vehicle roof structures to
strengthen the roof and support the roof rails. Current roof rail
designs include a rail that extends transversely across the vehicle
roof from one roof rail to the other roof rail and have a
substantially uniform width as measured in the fore-and-aft
direction. Such roof rails do not include lateral supporting
reinforcements between the windshield header rail, the rail
extending between the B-pillars, and the rail extending between the
C-pillars.
[0004] Vehicles are subjected to Federal Motor Vehicle Safety
Standards (FMVSS) tests in the United States. In FMVSS Side Pole
Impact Tests a pole is impacted by the test vehicle that may engage
the vehicle in a location where the roof rail is not supported by a
transversely extending rail. The unsupported portion of the roof
rail may allow unacceptable intrusions into the passenger
compartment. Vehicles are also subjected to FMVSS Roof Crush Tests
that apply an impact load to the vehicle roof in the area of the
roof rail.
[0005] Improving test results in the above FMVSS tests is normally
addressed by increasing the section size and the thickness of the
parts of the roof rail. Increasing the section size and thickness
of the roof rails adds weight to the vehicle and may reduce
visibility below the roof rail. It is a current objective to reduce
vehicle weight to achieve greater fuel efficiency. Any increase in
weight is considered to be a problem.
[0006] The use of a K-shaped roof bow has been proposed to improve
test performance that is joined to the roof rail by welds and
rivets. A K-shaped roof bow joined by welds or rivets to the roof
rail may separate in the test and limit the effectiveness of such a
design in transferring loads from the roof rails to the K-shaped
roof bow.
[0007] This disclosure is directed to addressing the above problems
and other problems as summarized below.
SUMMARY
[0008] According to one aspect of this disclosure, a roof bow is
provided for a vehicle having a roof. The roof bow includes a
central portion that extends transversely across the roof. The roof
bow also includes a first side portion on a first lateral end of
the central portion. A second side portion is provided on a second
lateral end of the central portion. The first and second side
portions may be first and second triangular portions that each
define a triangular opening.
[0009] According to other aspects of this disclosure, the roof bow
may include a lower shell that includes a lower portion of the
central portion, the first triangular portion and second triangular
portion. The roof bow also may include an upper shell that includes
an upper portion of the central portion, the first triangular
portion and second triangular portion. The lower shell and the
upper shell are joined together in a clam shell assembly. The upper
and lower shells are sheet metal stampings that are formed of
aluminum. The upper and lower shells are welded together about
their perimeter.
[0010] According to an alternative embodiment of this disclosure,
the roof bow may include a front extrusion that includes a front
portion of the central portion and a front leg of the first
triangular portion and a front leg of the second triangular
portion. A rear extrusion may include a rear portion of the central
portion and a rear leg of the first triangular portion and a rear
leg of the second triangular portion. A right side leg extrusion
may is joined to the front leg of the first triangular portion and
the rear leg of the first triangular portion. A left side leg
extrusion is joined to the front leg of the second triangular
portion and the rear leg of the second triangular portion. The
front legs of the front extrusion and the rear legs of the rear
extrusion may be joined to the right and left side extrusions by a
miter joint. The right and left side leg extrusions may each define
a plurality of access openings for joining the roof bow to the
vehicle.
[0011] According to further aspects of this disclosure, the
triangular portions each include a front leg that extends outwardly
in a forward direction, a rear leg that extends outwardly in a
rearward direction and a side leg that is joined to the front leg
and rear leg and extends in a longitudinal vehicle direction. The
side legs may each define a plurality of access openings for
joining the roof bow to the vehicle.
[0012] The roof bow may include a front step flange and a rear step
flange that both extend across the first side portion, the central
portion, and the second side portion. The roof bow may also include
a forward rib and a rearward rib that extend laterally across the
roof bow and diverge outwardly in the first and second side
portions.
[0013] According to another aspect of this disclosure as it relates
to a support structure for a vehicle roof panel, an outer roof
panel is disclosed that is supported by a right roof rail on a
right side of the outer roof panel and a left roof rail on a left
side of the outer roof panel. A roof bow includes a central portion
extending transversely across the roof with a first triangular
portion on a first lateral end of the central portion that defines
a first triangular opening. A second triangular portion on a second
lateral end of the central portion defines a second triangular
opening. A right side bracket may be attached to the right side
roof rail and the first triangular portion. A left side bracket may
be attached to the left side roof rail and the second triangular
portion.
[0014] According to other aspects of the disclosed roof, a right
B-pillar and a left B-pillar are provided and the right side
bracket and the left side bracket each extend both in front of and
in back of the B-pillars to a greater extent that the first and
second triangular portions of the roof bow. The right B-pillar and
the left B-pillar may be laterally aligned with the central
portion.
[0015] According to an additional aspect of this disclosure a
vehicle body structure is provided that includes an outer roof
panel and a roof rail supporting a side of the roof panel. A
B-pillar supports an intermediate portion of the roof rail and a
bracket is attached to the roof rail that extends fore-and-aft of
the B-pillar. A roof bow has a central portion that extends
transversely across the roof panel. A front leg extends outwardly
from the central portion in a forward direction to a longitudinally
extending side leg. A rear leg extends outwardly from the central
portion in a rearward direction to the side leg. An impact force
from a side impact collision test or a roof crush test with the
vehicle is transferred to the bracket. The bracket transfers the
impact force to the side leg. The side leg, in turn, transfers the
impact force to one or both of the front leg and the rear leg. The
front leg and rear leg then transfer the impact force to the
central portion of the roof bow.
[0016] According to other aspects of the vehicle body structure, a
lower shell may be provided that includes a lower portion of the
central portion, the front leg, the rear leg and the side leg. An
upper shell may be provided that includes an upper portion of the
central portion, the front leg, the rear leg and the side leg. The
lower shell and the upper shell may be joined together in a clam
shell assembly. The sheet metal stampings may be aluminum, and the
lower shell and the upper shell may be joined about a perimeter of
each by welding.
[0017] According to an alternative body structure, a front
extrusion may include a front portion of the central portion and
the front legs. A rear extrusion may include a rear portion of the
central portion and the rear legs. A side extrusion may be attached
to a distal end of each of the front legs and a distal end of each
of the rear legs with the side extrusion being attached to the
bracket.
[0018] The above aspects of this disclosure and other aspects are
described below in greater detail and with reference to the
attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1A is a top perspective view of the result of an impact
on the prior art roof design after a FMVSS Side Pole Impact
Test;
[0020] FIG. 1B is a diagrammatic view showing the load path for a
prior art roof structure in a FMVSS Side Pole Impact Test;
[0021] FIG. 2 is a fragmentary perspective view of a "bow-tie"
shaped roof bow assembled from extruded tubular component
parts;
[0022] FIG. 3A is a perspective view of the "bow-tie" shaped roof
bow shown in FIG. 2;
[0023] FIG. 3B is a fragmentary perspective view of a roof
structure including the bow-tie roof bow shown in FIG. 2 attached
to brackets and roof rails on opposite sides of a vehicle;
[0024] FIG. 4 is a perspective view of a bow-tie roof bow made with
a clamshell construction;
[0025] FIG. 5 is an exploded perspective view of the bow-tie roof
bow of FIG. 4 made having a clamshell construction with the two
parts of the clamshell separated from each other;
[0026] FIG. 6 is a fragmentary perspective view of a roof structure
including a bow-tie roof bow of FIG. 4 made with a clamshell
construction attached to right and left brackets and right and left
roof rails in the area of the B-pillar;
[0027] FIG. 7 is a perspective view of a "bow-tie" shaped roof bow
formed as a one-piece sheet metal stamping;
[0028] FIG. 8 is a cross-sectional view taken along the line 8-8 in
FIG. 7;
[0029] FIG. 9 is a chart of a test of roof rail intrusion comparing
an all-aluminum roof bow to a bow-tie roof bow design in a 20 mph
FMVSS Side Pole Impact Test; and
[0030] FIG. 10 is a chart of a 5 mph FMVSS roof crush test
comparing a baseline all-aluminum bow to the bow-tie shaped roof
bow design.
DETAILED DESCRIPTION
[0031] The illustrated embodiments are disclosed with reference to
the drawings. However, it is to be understood that the disclosed
embodiments are intended to be merely examples that may be embodied
in various and alternative forms. The figures are not necessarily
to scale and some features may be exaggerated or minimized to show
details of particular components. The specific structural and
functional details disclosed are not to be interpreted as limiting,
but as a representative basis for teaching one skilled in the art
how to practice the disclosed concepts.
[0032] Referring to FIG. 1A, a vehicle 10 made according to the
teachings of the prior art is shown following a FMVSS side pole
impact test. The vehicle 10 includes a roof rail 12 that extends
along the side of the vehicle 10. A-pillar 14 supports a windshield
header 16. B-pillar 18 is aligned with a central bow 20. The roof
rail 12 extends from the A-pillar 14 to the B-pillar 18. A circle
22 indicates the intrusion area with the vehicle 10 contact at a
pole 26, as shown in FIG. 1B.
[0033] Referring to FIG. 1B, the pole 26 is shown engaging the
prior art roof rail 12 between the A-pillar 14 and the B-pillar 18.
The impact force depicted in arrows showing that part of the force
follows the direction of arrow A1 that, in turn, transfers the
force to the windshield header 16, as indicated by the arrow A2.
Another portion of the force depicted by arrow A3 showing force
being transferred through the roof rail 12 to the central bow 20,
as indicated by arrow A4.
[0034] Referring to FIGS. 2, 3A and 3B, a right roof rail 30 and a
left roof rail 32 are connected by a bow-tie roof bow 36. The
bow-tie roof bow 36 in this embodiment is assembled from extruded
parts to provide a strong, lightweight roof bow. The bow-tie roof
bow 36 includes a central portion 38 that extends between a right
triangular portion 40 and a left triangular portion 42. A right
bracket 44 and a left bracket 46 are attached to the right roof
rail 30 and left roof rail 32, respectively. The right triangular
portion 40 and left triangular portion 42 are connected to the
right bracket 44 and left bracket 46, respectively.
[0035] A front extrusion 48 and rear extrusion 50 are assembled
together to form the central portion 38 and the right and left
triangular portions 40 and 42. A rear extrusion 50 is assembled to
the front extrusion 48. The front extrusion 48 includes a front leg
52 that extends from the central portion to form the front of the
triangular portions 40 and 42. A rear leg 54 is part of the rear
extrusion 50 and forms a rear portion of the right and left
triangular portions 40 and 42. A right side extrusion 56 joins the
front leg 52 and rear leg 54 on the right side of the roof bow 36.
A left side extrusion 58 interconnects the front leg 52 and rear
leg 54 on the left side of the bow-tie roof bow 36. The front and
rear legs 52 and 54 are joined to the right side extrusion and left
side extrusion with a miter joint 60.
[0036] Access holes 62 are provided on the right side extrusion 56
and left side extrusion 58 for assembling fasteners or welding the
bow-tie roof bow 36 to the right bracket 44 and left bracket
46.
[0037] Referring to FIGS. 4 through 6, an alternative embodiment of
a bow-tie roof bow 64 is illustrated that has a clamshell
structure. The bow-tie roof bow 64 includes a central portion 68
that is flanked by a right triangular portion 70 and a left
triangular portion 72. The right triangular portion 70 is attached
to a right bracket 74. The left triangular portion 72 is connected
to a left bracket 76. The bow-tie roof bow 64 includes an upper
shell 78 and a lower shell 80 that are assembled together and
welded about their periphery to form the bow-tie roof bow 64. The
triangular portions 70, 72 each include a front leg 82 and a rear
leg 84 that extend forward and rearward, respectively, from the
central portion 68. The right triangular portion 70 also includes a
right side 86 and the left triangular portion 72 includes a left
side 88.
[0038] Access holes 90 are provided in the right side 86 and the
left side 88 to provide access for fasteners or welding.
[0039] In both the bow-tie roof bow 36 and bow-tie roof bow 64, the
roof bows are attached to the right brackets 44, 74 and left
brackets 46, 76. The right and left brackets have a greater
longitudinal extent than the right and left sides 86 and 88 and the
right side extrusion 56 and left side extrusion 58. The triangular
portions of the bow-tie roof bows 36 and 64 extend to a greater
extent longitudinally than the length of the connection between the
B-pillars 18 and roof rail 12. In the FMVSS Side Pole Impact Test,
the impact forces are transferred initially to the roof rail 12
then to one of the side brackets 76, 78. The forces are then
transferred to the sides 56, 58, 86, 88. The impact forces are then
transmitted to the central portions 38, 68 through the front legs
52, 82 and rear legs 54, 84.
[0040] Referring to FIGS. 7 and 8, an alternative embodiment of a
"bow-tie" shaped roof bow 100 is illustrated that may be formed in
a sheet metal stamping operation. The stamped roof bow 100 includes
a central portion 102, a right side portion 104, and a left side
portion 106. The right side portion 104 is attached to a right
bracket 108. The left side portion 106 is attached to a left
bracket (not shown) that is a mirror image of the right bracket
108. The right bracket 108 is attached to a roof rail 110 of the
vehicle. The side portions 104 and 106 are wider than the central
portion 102 and are at least twice as wide as the central portion
102.
[0041] A front step flange 112 is formed at a front edge 114 of the
roof bow 100. A rear step flange 116 is formed at a rear edge 118
of the roof bow 100. A forward rib 120 extends laterally across the
roof bow 100 and a rearward rib 122 extends laterally across the
roof bow 100. The forward rib 120 and rearward rib 122 diverge in
the side portions 104 and 106 and are parallel to each other in the
central portion 102. The step flanges 112 and 116 and the ribs 120
and 122 function to reinforce the roof bow 100.
[0042] Referring to FIG. 9, the bow-tie roof bows are shown
compared to a baseline all aluminum roof bow. In the chart of FIG.
7, the baseline all-aluminum roof bows represented by the line A
and the bow-tie roof bow is represented by line B. Comparing line B
to line A, the intrusion is reduced by approximately 10 mm
beginning at approximately 60 milliseconds into the test through 90
milliseconds into the test. Reducing intrusion by 10 mm represents
a substantial improvement in roof bow performance in the 20 mph
FMVSS Side Pole Impact Test.
[0043] Referring to FIG. 10, another chart is provided of a 5 mph
Roof Crush Test. Again, the baseline all-aluminum roof bow is
represented by line A and the bow-tie roof bow design is
represented by line B. This test result shows that the bow-tie roof
bow design increases the force in MPAs of approximately 20 MPAs
when averaged over the period of the test from approximately 30 mm
to 80 mm. This represents an improvement of approximately 20%
compared to the baseline all aluminum roof bow design.
[0044] While exemplary embodiments are described above, it is not
intended that these embodiments describe all possible forms of the
disclosed apparatus and method. Rather, the words used in the
specification are words of description rather than limitation, and
it is understood that various changes may be made without departing
from the spirit and scope of the disclosure as claimed. The
features of various implementing embodiments may be combined to
form further embodiments of the disclosed concepts.
* * * * *