US20150217812A1 - Vehicle roof structure - Google Patents
Vehicle roof structure Download PDFInfo
- Publication number
- US20150217812A1 US20150217812A1 US14/174,103 US201414174103A US2015217812A1 US 20150217812 A1 US20150217812 A1 US 20150217812A1 US 201414174103 A US201414174103 A US 201414174103A US 2015217812 A1 US2015217812 A1 US 2015217812A1
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- United States
- Prior art keywords
- bracket
- roof
- vehicle
- roof panel
- vehicle body
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- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
- B62D—MOTOR VEHICLES; TRAILERS
- B62D27/00—Connections between superstructure or understructure sub-units
- B62D27/02—Connections between superstructure or understructure sub-units rigid
- B62D27/026—Connections by glue bonding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
- B62D—MOTOR VEHICLES; TRAILERS
- B62D25/00—Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for
- B62D25/06—Fixed roofs
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
- B23K31/02—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to soldering or welding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
- B62D—MOTOR VEHICLES; TRAILERS
- B62D27/00—Connections between superstructure or understructure sub-units
- B62D27/04—Connections between superstructure or understructure sub-units resilient
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
- B62D—MOTOR VEHICLES; TRAILERS
- B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
- B62D29/008—Superstructures, understructures, or sub-units thereof, characterised by the material thereof predominantly of light alloys, e.g. extruded
Definitions
- Automotive paint consists of a number of layers, applied separately and then cured at an elevated temperature. The paint is cured by passing the painted body through one or more paint bake ovens to raise the body temperature to about 180-200° C. and maintain it at that temperature for at least 20 minutes. This elevated temperature may be sufficient to initiate plastic deformation in the aluminum roof panel. Since plastic deformation is not reversed on cooling, any such deformation may result in an appearance feature such as a crease or buckle in the roof panel which could be unacceptable to the customer.
- the current joining process uses the paint bake ovens to cure the adhesive bonding the aluminum roof panel to the steel body panel.
- the heat from the paint bake ovens can cause distortion of the aluminum roof panel relative to the steel body, creating a bowing effect. If left unconstrained, the roof panel would bow enough to break the adhesive bond between the roof panel and vehicle body.
- a vehicle assembly comprises a roof structure including a roof panel formed of aluminum or an aluminum-based alloy and a vehicle body supporting the roof structure and formed of steel or a steel alloy.
- the vehicle body includes a pair of laterally spaced side panels, a front roof rail and a rear roof rail. Each roof rail spans between the side panels.
- At least one bracket secures the roof structure to the vehicle body.
- the bracket has a first portion fastened to the roof panel and a second portion extending away from the roof structure and welded to the vehicle body.
- the bracket is formed of steel or a steel alloy. An adhesive located inward of the weld connection of the vehicle body and second portion of the bracket bonds the second portion to the vehicle body.
- the adhesive seals the fastened connection of the roof panel and first portion of the bracket from moisture to prevent galvanic corrosion between the dissimilar materials of the roof panel and bracket.
- the adhesive further reduces thermal distortion of the attached roof panel relative to the vehicle body when the vehicle assembly is heated in a paint bake oven during the manufacture of the vehicle assembly.
- a vehicle assembly comprises a vehicle roof structure including a roof panel and a vehicle body.
- the vehicle roof structure is formed of aluminum or an aluminum-based alloy.
- the vehicle body includes a pair of laterally spaced side panels and a front roof rail and a rear roof rail spanning between the side panels. The side panels together with the front and rear roof rails support the vehicle roof structure.
- the vehicle body is formed of steel or a steel alloy.
- a pair of side brackets connects the side panels to roof panel, a front bracket connects the front roof rail to the roof panel, and a rear bracket connects the rear roof rail to the roof panel.
- Each bracket has a first portion fastened to the roof panel and a second portion extending outwardly of the roof panel and welded to the vehicle body.
- Each bracket is formed of steel of a steel alloy.
- the vehicle roof structure is bonded to the vehicle body via an adhesive.
- Each of the brackets provides a continuous vertical spacing between the roof panel and the vehicle body of approximately 4 mm to approximately 6 mm, and the adhesive is provided in the spacing.
- the adhesive seals the fastened connection of the roof panel and first portion of the bracket from moisture to prevent galvanic corrosion between the dissimilar materials of the roof panel and bracket.
- the adhesive further reduces thermal distortion of the attached roof panel relative to the vehicle body when the vehicle assembly is heated in a paint bake oven during the manufacture of the vehicle assembly.
- a method of assembling a vehicle comprises providing a vehicle body formed of steel or a steel alloy, the vehicle body includes a pair of laterally spaced side panels, a front roof rail and a rear roof rail, each roof rail spans between the side panels; providing a vehicle roof structure formed of aluminum or an aluminum-based alloy, the vehicle roof structure includes a roof panel having a flange structure provided at a peripheral edge portion, the flange portion including a vertical wall and a horizontal surface; applying an adhesive on the horizontal surface of the flange structure around an entire perimeter of the roof panel; providing a pair of side brackets, a front bracket and a rear bracket, each bracket formed of steel or a steel alloy, and positioning each of the brackets on the flange structure such that the adhesive is between each bracket and the flange structure; positioning the vehicle roof structure together with the brackets on the vehicle body; fastening each of the brackets to the vertical wall of the flange structure; welding the side brackets to the side panels, the front bracket to the front
- FIG. 1 is an exploded perspective view of a vehicle assembly including a vehicle body formed of steel or a steel alloy and a vehicle roof structure formed of aluminum or an aluminum-based alloy.
- FIG. 2 is a cross-sectional view taken along a side portion of the vehicle assembly.
- FIG. 3 is a cross-sectional view taken along a forward portion of the vehicle assembly.
- FIG. 4 is a cross-sectional view taken along a rearward portion of the vehicle assembly according to one aspect of the present disclosure.
- FIG. 5 is a cross-sectional view taken along a rearward portion of the vehicle assembly according to another aspect of the present disclosure.
- FIGS. 6A , 6 B and 6 C illustrate thermal distortion of the attached roof panel relative to the vehicle body when the vehicle assembly is heated in a paint bake oven during the manufacture of the vehicle assembly.
- the exemplary vehicle assembly 100 which has an aluminum or aluminum-based alloy roof structure 102 attached to a steel or steel alloy vehicle body 104 .
- the vehicle body 104 includes a pair of laterally spaced body members or side panels 112 , 114 for defining sides of a passenger compartment 116 and a front roof rail 118 and a rear roof rail 120 spanning between the side panels.
- the body members 112 , 114 may be identically constructed, but for their disposition on opposite sides of the vehicle assembly 100 .
- At least one cross member or roof bow 122 can be interposed between the front and rear roof rails 118 , 120 and extends between the spaced body members 112 , 114 .
- the side panels together with the front and rear roof rails 118 , 120 support the roof structure 102 over the passenger compartment 116 .
- Attached to the vehicle body 104 is the exemplary vehicle roof structure 102 .
- the vehicle roof structure 102 includes an aluminum or aluminum-based alloy roof panel 132 which overlies the passenger compartment 116 .
- the roof panel 132 can include stiffening ribs 134 adapted to accommodate loads imparted on the roof panel by articles transported thereon, for example in a luggage rack. These ribs are commonly used on vehicles such as SUVs or vans because the roof panels for these vehicles are extensive and generally flat.
- the ribs 134 stiffen the roof panel 132 and help it to maintain its shape. For roof panels used in smaller vehicles, such as sedans, these ribs are generally not required.
- the roof panel 132 is generally rectangular in plan view but because individual vehicle roof structures are required to conform to vehicle styling, the roof panel can have alternative shapes.
- the roof panel 132 includes a forward end portion 140 , a rearward end portion 142 and opposite side portions 144 , 146 which extend longitudinally between the forward and rearward end portions.
- the vehicle roof assembly 102 further includes at least one roof stiffener which extends between the side portions 144 , 146 .
- a roof stiffener (not shown) can overlie the roof bow 122 ; although the roof stiffener is not required.
- an opening can be provided in the roof panel 132 for a sunroof assembly (not shown).
- At least one bracket formed of steel or a steel alloy secures the roof structure 102 to the vehicle body 104 .
- the at least one bracket has a first portion fastened to the roof panel 132 and a second portion extending away from the roof structure 102 and welded to the vehicle body 104 .
- the roof panel 132 includes an upper horizontal surface 150 connected to a flange structure 152 provided at a peripheral edge portion of the upper horizontal surface.
- the flange structure 152 extends about the entire peripheral edge portion of the upper horizontal surface 150 .
- the flange structure 152 is generally defined by a vertical wall and a lower horizontal surface (lower relative to the upper horizontal surface 150 ).
- the bracket first portion is fastened to the vertical wall and the bracket second portion is adhered or bonded to the lower horizontal surface.
- the at least one bracket includes a pair of side brackets 160 , 162 , a front bracket 164 and a rear bracket 166 .
- the side brackets 160 , 162 extend longitudinally on the roof panel 132 between the forward and rearward end portions 140 , 142 of the roof panel 132 and connect the side panels 112 , 114 to the respective side portions 144 , 146 of the roof panel 132 .
- the front bracket 164 extends laterally across the roof panel 132 between the side portions 144 , 146 and connects the front roof rail 118 to the forward end portion 140 of the roof panel 132 .
- the rear bracket 166 also extends laterally across the roof panel 132 between the side portions 144 , 146 and connects the rear roof rail 120 to the rearward end portion 142 of the roof panel 132 .
- Each bracket 160 , 162 , 164 , 166 is separate from the roof panel 132 and is fixedly secured thereto to facilitate attachment of the roof panel and vehicle body 104 .
- the brackets 160 , 162 , 164 , 166 can be separate from each other or can be formed as a unitary-one piece member, such as a single frame. As shown in FIG. 1 , together the four brackets 160 , 162 , 164 , 166 extend approximately an entire perimeter of the roof panel 132 .
- FIG. 2 depicts the side panel 112 connected to the side portion 144 via the side bracket 160 .
- the side panel 112 includes an outer panel 170 and an inner panel 172 .
- a reinforcement (not shown) can be interposed between the outer and inner panels.
- the outer panel 170 includes a flange structure having vertical wall 176 and a horizontal wall 178 .
- the inner panel 172 also includes a flange structure having a horizontal wall 182 .
- the respective horizontal walls 178 , 182 of the outer panel 170 and inner panel 172 have complementary forms which nest and are welded together.
- the side portion 144 of the roof panel 132 includes a side section 190 of the peripheral flange structure 152 having a vertical wall 192 and a lower horizontal surface 194 (lower relative to the upper horizontal surface 150 ).
- the respective flange structures of the side panel 112 and roof panel 132 define a roof groove 198 having provided therein mounting studs 200 for the attachment of a roof molding (not shown).
- Each mounting stud 200 can be fixedly attached (e.g., welded) to the horizontal walls 178 , 182 of the outer panel 170 and inner panel 172 .
- the side bracket 160 connects the side panel 112 to the side section 190 of the peripheral flange structure 152 of the roof panel side portion 144 .
- the side bracket 160 includes a first portion 210 and a second portion 212 .
- the first portion 210 is fastened to the vertical wall 192 .
- the second portion 212 extends outwardly from the roof panel 132 a distance approximately equal to a distance or spacing between the outer panel 170 and the roof panel. This allows the second portion 212 to be both adhered or bonded to the lower horizontal surface 194 and fixedly attached (e.g., welded) to the horizontal wall 178 of the outer panel 170 . As depicted in FIG.
- the side bracket 160 is substantially L-shaped and the first portion 210 of the side bracket 160 is a vertical leg 216 and the second portion 212 is a horizontal leg 218 .
- the vertical leg 216 is connected to an interior of the roof panel vertical wall 192 by any mechanical means known in the art, such as but not limited to the illustrated clinching of the vertical leg 216 to the vertical wall 192 .
- the vertical leg 216 can be welded to the vertical wall 192 or connected by use of self piercing rivets, bolts, etc.
- the horizontal leg 218 has a stepped configuration including an upper section 220 (i.e., a section closer to the upper horizontal surface 150 of the roof panel 132 ) and a lower section 222 .
- the upper section 220 of the horizontal leg 218 is adhered or bonded to the lower horizontal surface 194 of the roof panel 132 via an electrically nonconductive adhesive 230 .
- the connection between the first portion 210 of the side bracket 160 and the vertical wall 192 of the roof panel 132 is positioned inwardly of the adhesive 230 .
- the lower section 222 extends outward beyond an end of the lower horizontal surface 194 and is dimensioned approximately equal to a dimension of the horizontal wall 178 of the outer panel 170 . This allows the lower section to be nested with and fixedly attached (e.g., welded) to the respective horizontal walls 178 , 182 of the outer panel 170 and inner panel 172 .
- the mounting stud 200 can be fixedly attached (e.g., welded) to the lower section 222 .
- FIG. 3 depicts the front roof rail 118 connected to the forward end portion 140 of the roof panel 132 via the front bracket 164 .
- the front roof rail 118 includes an outer panel 240 and an inner panel 242 .
- a reinforcement (not shown) can be interposed between the outer and inner panels.
- the outer panel 240 includes a flange structure having vertical wall 246 and a horizontal wall 248 .
- the horizontal wall 248 can have stepped configuration and includes a depressed section 250 extending from the vertical wall 246 .
- the inner panel 242 also includes a flange structure having a horizontal wall 152 .
- the depressed section 250 of the outer panel horizontal wall 248 is fixedly attached (e.g., welded) to the inner panel horizontal wall 252 .
- the forward end portion 140 of the roof panel 132 includes a forward section 260 of the peripheral flange structure 152 having a vertical wall 262 and a lower horizontal surface 264 (lower relative to the upper horizontal surface 150 ).
- the lower horizontal surface 264 extends beneath an end portion of a windshield 270 mounted to the vehicle body 104 .
- the front bracket 164 connects the front roof rail 118 to the forward section 260 of the peripheral flange structure 152 of the roof panel forward end portion 140 .
- the front bracket 164 includes a first portion 280 and a second portion 282 .
- the first portion 280 is fastened to the vertical wall 262 .
- the second portion 282 extends outwardly from the roof panel 132 a distance approximately equal to a distance the horizontal wall 248 of the outer panel 240 extends outwardly from the roof panel 132 . This allows the second portion 282 to be both adhered or bonded to the lower horizontal surface 264 and fixedly attached (e.g., welded) to the horizontal wall 248 of the outer panel 240 . As depicted in FIG.
- the front bracket 164 is substantially L-shaped and the first portion 280 of the front bracket 164 is a vertical leg 286 and the second portion 282 is a horizontal leg 288 .
- the vertical leg 286 is connected to an interior of the roof panel vertical wall 262 by any mechanical means known in the art, such as but not limited to the illustrated clinching of the vertical leg 286 to the vertical wall 262 .
- the vertical leg 286 can be welded to the vertical wall 262 or connected by use of self piercing rivets, bolts, etc.
- the horizontal leg 288 has a stepped configuration including an upper section 290 (i.e., a section closer to the upper horizontal surface 150 of the roof panel 132 ) and a lower section 292 .
- the lower section 292 of the horizontal leg 288 is aligned with the depressed section 250 and is adhered or bonded to the lower horizontal surface 264 of the roof panel 132 via the electrically nonconductive adhesive 230 .
- the upper section 290 extends outward beyond an end of the lower horizontal surface and is fixedly attached (e.g., welded) to the horizontal wall 248 of the outer panel 240 .
- the end portion of the windshield 270 is adhesively bonded to the upper section 290 of the front bracket 164 .
- FIG. 4 depicts the rear roof rail 120 connected to the rearward end portion 142 of the roof panel 132 via the rear bracket 166 .
- the rear roof rail 120 includes an outer panel 300 and an inner panel 302 .
- a reinforcement (not shown) can be interposed between the outer and inner panels.
- the outer panel 300 includes a flange structure having vertical wall 306 and a horizontal wall 308 .
- An end portion 310 of the horizontal wall 308 can be angled; although, this is not required.
- the inner panel 302 also includes a flange structure having a horizontal wall 312 which is fixedly attached (e.g., welded) to the outer panel horizontal wall 308 .
- the rearward end portion 142 of the roof panel 132 includes a rearward section 320 of the peripheral flange structure 152 having a vertical wall 322 and a lower horizontal surface 324 (lower relative to the upper horizontal surface 150 ).
- the rear bracket 166 connects the rear roof rail 120 to the rearward section 320 of the peripheral flange structure 152 of the roof panel rearward end portion 142 .
- the rear bracket 166 includes a first portion 330 and a second portion 332 .
- the first portion 330 is fastened to the vertical wall 322 .
- the second portion 332 extends outwardly from the roof panel 132 a distance approximately equal to a distance the horizontal wall 308 of the outer panel 300 extends outwardly from the roof panel 132 .
- the rear bracket 166 is substantially L-shaped and the first portion 330 of the rear bracket 166 is a vertical leg 336 and the second portion 332 is a horizontal leg 338 .
- the vertical leg 336 is connected to an interior of the roof panel vertical wall 322 by any mechanical means known in the art, such as but not limited to the illustrated clinching of the vertical leg 336 to the vertical wall 332 .
- the vertical leg 336 can be welded to the vertical wall 322 or connected by use of self piercing rivets, bolts, etc.
- the horizontal leg 338 has a stepped configuration including an upper section 340 (i.e., a section closer to the upper horizontal surface 150 of the roof panel 132 ) and a lower section 342 .
- the lower section 342 of the horizontal leg 338 can be angled to match the angled end portion 310 of the outer panel horizontal wall 308 . According to the embodiment of FIG.
- the upper section 340 is adhered or bonded to the lower horizontal surface 324 of the roof panel 132 via the electrically nonconductive adhesive 230 .
- the lower section 342 extends outward beyond an end of the lower horizontal surface 324 and is fixedly attached (e.g., welded) to the end portion 310 of the horizontal wall 308 of the outer panel 300 .
- FIG. 5 shows another aspect of a rear bracket 166 ′ for connecting a rear roof rail 120 ′ to the peripheral flange structure 152 of the roof panel 132 .
- the rear bracket 166 ′ includes a first portion 330 ′ attached to the vertical wall 332 of the flange structure 152 .
- a second portion 332 ′ of the rear bracket 166 ′ is shorter in length than a horizontal wall 308 ′ of an outer panel 308 ′ of the rear roof rail 120 ′. This allows a lower section 342 ′ of the second portion 332 ′ to be nested with and fixedly attached (e.g., welded) to the respective horizontal walls 308 ′, 312 ′ of the outer panel 300 ′ and inner panel 302 ′.
- An upper section 340 ′ of the second portion 332 ′ is adhered or bonded to the lower horizontal surface 324 of the roof panel 132 via the electrically nonconductive adhesive 230 .
- the locations of the fastened connections (e.g., clinching) between the first portion 210 , 280 , 330 of each of the brackets 160 , 162 , 164 , 166 and the roof panel 132 is generally dictated by the need for the strength of the attachment between the vehicle roof structure 102 and vehicle body 104 and more, closely-spaced, connections will promote stronger attachment.
- distortion of the roof panel 132 can be minimized when fewer connections are employed, and the brackets 160 , 162 , 164 , 166 together with the adhesive 230 provides the required attachment strength between the vehicle roof structure 102 and the vehicle body 104 .
- each of the brackets 160 , 162 , 164 , 166 maintains a continuous spacing or gap between the roof panel 132 of the vehicle roof structure 102 and the vehicle body 104 of approximately 4 mm to approximately 6 mm, and the adhesive 230 is provided in the spacing.
- this continuous spacing provided by brackets 160 , 162 , 164 , 166 for the adhesive 230 is in the vertical or height direction between the roof panel 132 and the second portions 212 , 282 , 332 of the brackets 160 , 162 , 164 , 166 which connect the roof panel 132 to the vehicle body 104 .
- the continuous vertical spacing between the roof panel 132 and the vehicle body 104 is approximately 5 mm.
- rigidly attaching the aluminum-based alloy vehicle roof structure 102 to the steel vehicle body 104 i.e., vehicle components with dissimilar coefficients of thermal expansion—about 22.5 ⁇ 10 ⁇ 6 m/m K for aluminum and about 13 ⁇ 10 ⁇ 6 m/m K for steel
- the roof panel 132 of the vehicle roof structure attached to the vehicle body 104 will be subjected to compressive thermal stresses with increase in temperature, the thermal stresses increasing generally in proportion to the temperature.
- the vehicle assembly 100 After assembly, but before attachment of closures such as doors or hoods, the vehicle assembly 100 is washed and then painted.
- the paint must be cured by exposure to elevated temperatures, requiring that the vehicle assembly 102 to pass through at least one paint bake oven, subjecting the vehicle assembly to temperatures of up to 200° C. for a period of not less than 20 minutes. This temperature establishes the greatest compressive stress developed in the vehicle roof structure.
- the roof panel 132 when subjected to compressive loads or stresses may deform, forming a buckle. If the buckling stress exceeds the yield stress of the metal of the roof panel, the buckle will be permanent and the roof panel 132 will not adopt its original configuration even after even after the vehicle assembly 100 exits the oven and cools.
- FIG. 6A shows a pre-bake condition of the vehicle assembly 100 .
- FIG. 6B shows the vehicle assembly 100 in a baking condition.
- the adhesive 230 absorbs the expansion.
- FIG. 6C the roof panel 132 returns to the pre-bake condition.
- the continuous spacing or gap provided by the brackets 160 , 162 , 164 , 166 for the adhesive 230 allows the aluminum roof panel 132 to distort during baking and curing of the adhesive (e.g., during an e-coat process) and allows shearing of the adhesive without the adhesive failing and without deformation of either the roof panel 132 or the side panel 112 .
- the adhesive 230 forms the primary connection between the second portions 212 , 282 , 332 of the brackets 160 , 162 , 164 , 166 and the roof panel 132 , whereas the fastened connection (e.g., clinching) of the first portions 210 , 280 , 330 of the brackets to the roof panel 132 is more for positioning the roof panel and the brackets together prior to curing of the adhesive 230 .
- the adhesive 230 provides flexibility during heating of the vehicle body to help absorb the stress associated with the different expansion rates of the dissimilar materials.
- the depicted fastened (e.g. clinched) area is in a dry section because the adhesive 230 seals the connection of the brackets 160 , 162 , 164 , 166 and the roof panel 132 from moisture to prevent galvanic corrosion between the dissimilar materials.
- the present disclosure provides a method of assembling a vehicle including the vehicle body 104 formed of steel or a steel alloy and the vehicle roof structure 100 formed of aluminum or an aluminum-based alloy.
- the method comprises providing the vehicle body 102 including the pair of laterally spaced side panels 112 , 114 , the front roof rail 118 and the rear roof rail 120 ; providing the vehicle roof structure 102 including the roof panel 132 having the flange structure 152 provided at a peripheral edge portion; applying the adhesive 230 on the horizontal surface 194 , 264 , 324 of the flange structure 152 around an entire perimeter of the roof panel 132 ; positioning each of the brackets 160 , 162 , 164 , 166 on the flange structure 152 such that the adhesive 230 is between each bracket and the flange structure; positioning the vehicle roof structure 102 together with the brackets 160 , 162 , 164 , 166 on the vehicle body 104 ; fastening each of the brackets 160 , 162 , 164 , 166 to the vertical wall 192 , 262 , 322 of the flange structure 152 (e.g., by clinching, welding, fasteners); welding the side brackets 160 ,
- the exemplary method further comprises providing a continuous vertical spacing between the roof panel 132 and the vehicle body 104 of approximately 4 mm to approximately 6 mm by use of the side brackets, front bracket and rear bracket, and providing the adhesive 230 in the spacing; positioning the fastened connection between the brackets 160 , 162 , 164 , 166 and the flange structure 152 inwardly of the adhesive 230 , and positioning the welded connection between the brackets 160 , 162 , 164 , 166 and the vehicle body 104 outwardly of the adhesive 230 .
- the method further includes clinching the respective vertical leg 216 , 286 336 of each bracket 160 , 162 , 164 , 166 to an interior of the flange structure vertical wall 192 , 262 , 322 , and for each of the side panel brackets 160 , 162 and the rear bracket 166 , bonding the upper section 218 , 340 of the horizontal leg 220 , 338 to the horizontal surface 194 , 324 of the flange structure 152 , and for the front bracket 164 bonding the lower section 292 of the horizontal leg 288 to the horizontal surface 264 of the flange structure 152 .
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Abstract
Description
- The substitution of aluminum or aluminum-based alloy roof panels for the low-carbon steel or steel alloy roof panels most commonly used in motor vehicles is an attractive option for vehicle mass reduction. Often, however, the remainder of the vehicle body structure continues to be fabricated of steel. Joining an aluminum roof panel to a steel body panel is difficult due to the thermal expansion considerations of the dissimilar materials. The combination of the aluminum roof panel attached to the steel body may create compressive stresses in the aluminum roof panel when the body is subjected to elevated temperatures such as those required to cure or bake the paint applied to the body. These stresses may lead to unacceptable appearance features in the visible segment of the roof panel.
- Manufacturers currently secure the aluminum roof panel to the steel body panel after the weld process in assembly. This process typically includes an adhesive bonding operation. Self-piercing rivets can also be used to secure the aluminum roof panel to the steel body panel. This approach, though appealing from a vehicle mass-reduction viewpoint, raises issues due to the significantly different coefficients of thermal expansion of aluminum and steel (about 22.5×10−6 m/m K for aluminum and about 13×10−6 m/m K for steel). The adhesive must be able to absorb the distortion caused by the thermal expansion difference between the roof panel and the steel body panel. Further, because the steel and aluminum are permanently joined together by the rivets, this difference in thermal expansion of steel and aluminum will develop stresses in the aluminum and steel whenever the vehicle body temperature differs from the temperature at which the joint was made. The highest temperature experienced by the vehicle body is during manufacture, when the assembled body is painted. Automotive paint consists of a number of layers, applied separately and then cured at an elevated temperature. The paint is cured by passing the painted body through one or more paint bake ovens to raise the body temperature to about 180-200° C. and maintain it at that temperature for at least 20 minutes. This elevated temperature may be sufficient to initiate plastic deformation in the aluminum roof panel. Since plastic deformation is not reversed on cooling, any such deformation may result in an appearance feature such as a crease or buckle in the roof panel which could be unacceptable to the customer.
- Further, having the roof and vehicle body panels in contact or electrically connected can create galvanic corrosion. The risk for this corrosion is increased when water is present, such as in the roof gutter areas. As it relates to the adhesive, the current joining process uses the paint bake ovens to cure the adhesive bonding the aluminum roof panel to the steel body panel. However, the heat from the paint bake ovens can cause distortion of the aluminum roof panel relative to the steel body, creating a bowing effect. If left unconstrained, the roof panel would bow enough to break the adhesive bond between the roof panel and vehicle body.
- In accordance with one aspect, a vehicle assembly comprises a roof structure including a roof panel formed of aluminum or an aluminum-based alloy and a vehicle body supporting the roof structure and formed of steel or a steel alloy. The vehicle body includes a pair of laterally spaced side panels, a front roof rail and a rear roof rail. Each roof rail spans between the side panels. At least one bracket secures the roof structure to the vehicle body. The bracket has a first portion fastened to the roof panel and a second portion extending away from the roof structure and welded to the vehicle body. The bracket is formed of steel or a steel alloy. An adhesive located inward of the weld connection of the vehicle body and second portion of the bracket bonds the second portion to the vehicle body. The adhesive seals the fastened connection of the roof panel and first portion of the bracket from moisture to prevent galvanic corrosion between the dissimilar materials of the roof panel and bracket. The adhesive further reduces thermal distortion of the attached roof panel relative to the vehicle body when the vehicle assembly is heated in a paint bake oven during the manufacture of the vehicle assembly.
- In accordance with another aspect, a vehicle assembly comprises a vehicle roof structure including a roof panel and a vehicle body. The vehicle roof structure is formed of aluminum or an aluminum-based alloy. The vehicle body includes a pair of laterally spaced side panels and a front roof rail and a rear roof rail spanning between the side panels. The side panels together with the front and rear roof rails support the vehicle roof structure. The vehicle body is formed of steel or a steel alloy. A pair of side brackets connects the side panels to roof panel, a front bracket connects the front roof rail to the roof panel, and a rear bracket connects the rear roof rail to the roof panel. Each bracket has a first portion fastened to the roof panel and a second portion extending outwardly of the roof panel and welded to the vehicle body. Each bracket is formed of steel of a steel alloy. The vehicle roof structure is bonded to the vehicle body via an adhesive. Each of the brackets provides a continuous vertical spacing between the roof panel and the vehicle body of approximately 4 mm to approximately 6 mm, and the adhesive is provided in the spacing. The adhesive seals the fastened connection of the roof panel and first portion of the bracket from moisture to prevent galvanic corrosion between the dissimilar materials of the roof panel and bracket. The adhesive further reduces thermal distortion of the attached roof panel relative to the vehicle body when the vehicle assembly is heated in a paint bake oven during the manufacture of the vehicle assembly.
- In accordance with yet another aspect, a method of assembling a vehicle comprises providing a vehicle body formed of steel or a steel alloy, the vehicle body includes a pair of laterally spaced side panels, a front roof rail and a rear roof rail, each roof rail spans between the side panels; providing a vehicle roof structure formed of aluminum or an aluminum-based alloy, the vehicle roof structure includes a roof panel having a flange structure provided at a peripheral edge portion, the flange portion including a vertical wall and a horizontal surface; applying an adhesive on the horizontal surface of the flange structure around an entire perimeter of the roof panel; providing a pair of side brackets, a front bracket and a rear bracket, each bracket formed of steel or a steel alloy, and positioning each of the brackets on the flange structure such that the adhesive is between each bracket and the flange structure; positioning the vehicle roof structure together with the brackets on the vehicle body; fastening each of the brackets to the vertical wall of the flange structure; welding the side brackets to the side panels, the front bracket to the front roof rail and the rear bracket to the rear roof rail; and heating the vehicle body together with the vehicle roof structure and the brackets to a predetermined temperature to cure the adhesive.
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FIG. 1 is an exploded perspective view of a vehicle assembly including a vehicle body formed of steel or a steel alloy and a vehicle roof structure formed of aluminum or an aluminum-based alloy. -
FIG. 2 is a cross-sectional view taken along a side portion of the vehicle assembly. -
FIG. 3 is a cross-sectional view taken along a forward portion of the vehicle assembly. -
FIG. 4 is a cross-sectional view taken along a rearward portion of the vehicle assembly according to one aspect of the present disclosure. -
FIG. 5 is a cross-sectional view taken along a rearward portion of the vehicle assembly according to another aspect of the present disclosure. -
FIGS. 6A , 6B and 6C illustrate thermal distortion of the attached roof panel relative to the vehicle body when the vehicle assembly is heated in a paint bake oven during the manufacture of the vehicle assembly. - It should be understood that the description and drawings herein are merely illustrative and that various modifications and changes can be made in the structures disclosed without departing from the present disclosure. In general, the figures of the exemplary vehicle roof structure are not to scale. As used herein, lateral directions are transverse across the vehicle, i.e., left and right directions. Likewise, longitudinal directions refer to forward and rearward directions of vehicle travel, and the vertical directions relate to elevation, i.e., upward and downward directions. It will also be appreciated that the various identified components of the exemplary vehicle roof structure disclosed herein are merely terms of art that may vary from one manufacturer to another and should not be deemed to limit the present disclosure.
- Increasingly, low-carbon steel or steel alloys, long the material of choice for vehicle body construction, is being displaced by higher strength-to-weight ratio materials such as aluminum or aluminum-based alloys. This trend is driven by a desire to reduce vehicle weight for improved fuel economy. An example of this is the
exemplary vehicle assembly 100 which has an aluminum or aluminum-basedalloy roof structure 102 attached to a steel or steelalloy vehicle body 104. As schematically shown inFIG. 1 , thevehicle body 104 includes a pair of laterally spaced body members orside panels passenger compartment 116 and afront roof rail 118 and arear roof rail 120 spanning between the side panels. Thebody members vehicle assembly 100. At least one cross member orroof bow 122 can be interposed between the front andrear roof rails spaced body members roof structure 102 over thepassenger compartment 116. Attached to thevehicle body 104 is the exemplaryvehicle roof structure 102. - With reference to
FIG. 2 , thevehicle roof structure 102 includes an aluminum or aluminum-basedalloy roof panel 132 which overlies thepassenger compartment 116. Theroof panel 132 can include stiffeningribs 134 adapted to accommodate loads imparted on the roof panel by articles transported thereon, for example in a luggage rack. These ribs are commonly used on vehicles such as SUVs or vans because the roof panels for these vehicles are extensive and generally flat. Theribs 134 stiffen theroof panel 132 and help it to maintain its shape. For roof panels used in smaller vehicles, such as sedans, these ribs are generally not required. Theroof panel 132 is generally rectangular in plan view but because individual vehicle roof structures are required to conform to vehicle styling, the roof panel can have alternative shapes. Theroof panel 132 includes aforward end portion 140, arearward end portion 142 andopposite side portions vehicle roof assembly 102 further includes at least one roof stiffener which extends between theside portions vehicle assembly 100, a roof stiffener (not shown) can overlie theroof bow 122; although the roof stiffener is not required. As is well known, an opening (not shown) can be provided in theroof panel 132 for a sunroof assembly (not shown). - At least one bracket formed of steel or a steel alloy secures the
roof structure 102 to thevehicle body 104. As will be described in greater detail below, the at least one bracket has a first portion fastened to theroof panel 132 and a second portion extending away from theroof structure 102 and welded to thevehicle body 104. Theroof panel 132 includes an upperhorizontal surface 150 connected to aflange structure 152 provided at a peripheral edge portion of the upper horizontal surface. According to one aspect, theflange structure 152 extends about the entire peripheral edge portion of the upperhorizontal surface 150. Theflange structure 152 is generally defined by a vertical wall and a lower horizontal surface (lower relative to the upper horizontal surface 150). The bracket first portion is fastened to the vertical wall and the bracket second portion is adhered or bonded to the lower horizontal surface. - Particularly, the at least one bracket includes a pair of
side brackets front bracket 164 and arear bracket 166. Theside brackets roof panel 132 between the forward andrearward end portions roof panel 132 and connect theside panels respective side portions roof panel 132. Thefront bracket 164 extends laterally across theroof panel 132 between theside portions front roof rail 118 to theforward end portion 140 of theroof panel 132. Therear bracket 166 also extends laterally across theroof panel 132 between theside portions rear roof rail 120 to therearward end portion 142 of theroof panel 132. Eachbracket roof panel 132 and is fixedly secured thereto to facilitate attachment of the roof panel andvehicle body 104. Thebrackets FIG. 1 , together the fourbrackets roof panel 132. -
FIG. 2 depicts theside panel 112 connected to theside portion 144 via theside bracket 160. To simplify the explanation of the present disclosure, only the construction of theside panel 112 and its connection to thevehicle roof structure 102 will be discussed, but it should be understood that theside panel 114 can have the same construction with a similar connection to thevehicle roof structure 102. Theside panel 112 includes anouter panel 170 and aninner panel 172. As is well known, a reinforcement (not shown) can be interposed between the outer and inner panels. Theouter panel 170 includes a flange structure havingvertical wall 176 and ahorizontal wall 178. Theinner panel 172 also includes a flange structure having ahorizontal wall 182. The respectivehorizontal walls outer panel 170 andinner panel 172 have complementary forms which nest and are welded together. Theside portion 144 of theroof panel 132 includes aside section 190 of theperipheral flange structure 152 having avertical wall 192 and a lower horizontal surface 194 (lower relative to the upper horizontal surface 150). It should be appreciated that the respective flange structures of theside panel 112 androof panel 132 define aroof groove 198 having provided therein mountingstuds 200 for the attachment of a roof molding (not shown). Each mountingstud 200 can be fixedly attached (e.g., welded) to thehorizontal walls outer panel 170 andinner panel 172. - The
side bracket 160 connects theside panel 112 to theside section 190 of theperipheral flange structure 152 of the roofpanel side portion 144. Theside bracket 160 includes afirst portion 210 and asecond portion 212. Thefirst portion 210 is fastened to thevertical wall 192. Thesecond portion 212 extends outwardly from the roof panel 132 a distance approximately equal to a distance or spacing between theouter panel 170 and the roof panel. This allows thesecond portion 212 to be both adhered or bonded to the lowerhorizontal surface 194 and fixedly attached (e.g., welded) to thehorizontal wall 178 of theouter panel 170. As depicted inFIG. 2 , theside bracket 160 is substantially L-shaped and thefirst portion 210 of theside bracket 160 is avertical leg 216 and thesecond portion 212 is ahorizontal leg 218. Thevertical leg 216 is connected to an interior of the roof panelvertical wall 192 by any mechanical means known in the art, such as but not limited to the illustrated clinching of thevertical leg 216 to thevertical wall 192. For example, it should be appreciated that thevertical leg 216 can be welded to thevertical wall 192 or connected by use of self piercing rivets, bolts, etc. Thehorizontal leg 218 has a stepped configuration including an upper section 220 (i.e., a section closer to the upperhorizontal surface 150 of the roof panel 132) and alower section 222. Theupper section 220 of thehorizontal leg 218 is adhered or bonded to the lowerhorizontal surface 194 of theroof panel 132 via an electricallynonconductive adhesive 230. As such, the connection between thefirst portion 210 of theside bracket 160 and thevertical wall 192 of theroof panel 132 is positioned inwardly of the adhesive 230. Thelower section 222 extends outward beyond an end of the lowerhorizontal surface 194 and is dimensioned approximately equal to a dimension of thehorizontal wall 178 of theouter panel 170. This allows the lower section to be nested with and fixedly attached (e.g., welded) to the respectivehorizontal walls outer panel 170 andinner panel 172. The mountingstud 200 can be fixedly attached (e.g., welded) to thelower section 222. -
FIG. 3 depicts thefront roof rail 118 connected to theforward end portion 140 of theroof panel 132 via thefront bracket 164. Thefront roof rail 118 includes anouter panel 240 and aninner panel 242. As is well known, a reinforcement (not shown) can be interposed between the outer and inner panels. Theouter panel 240 includes a flange structure havingvertical wall 246 and ahorizontal wall 248. Thehorizontal wall 248 can have stepped configuration and includes adepressed section 250 extending from thevertical wall 246. Theinner panel 242 also includes a flange structure having ahorizontal wall 152. Thedepressed section 250 of the outer panelhorizontal wall 248 is fixedly attached (e.g., welded) to the inner panelhorizontal wall 252. Theforward end portion 140 of theroof panel 132 includes aforward section 260 of theperipheral flange structure 152 having avertical wall 262 and a lower horizontal surface 264 (lower relative to the upper horizontal surface 150). The lowerhorizontal surface 264 extends beneath an end portion of awindshield 270 mounted to thevehicle body 104. - The
front bracket 164 connects thefront roof rail 118 to theforward section 260 of theperipheral flange structure 152 of the roof panelforward end portion 140. Thefront bracket 164 includes afirst portion 280 and asecond portion 282. Thefirst portion 280 is fastened to thevertical wall 262. Thesecond portion 282 extends outwardly from the roof panel 132 a distance approximately equal to a distance thehorizontal wall 248 of theouter panel 240 extends outwardly from theroof panel 132. This allows thesecond portion 282 to be both adhered or bonded to the lowerhorizontal surface 264 and fixedly attached (e.g., welded) to thehorizontal wall 248 of theouter panel 240. As depicted inFIG. 3 , thefront bracket 164 is substantially L-shaped and thefirst portion 280 of thefront bracket 164 is avertical leg 286 and thesecond portion 282 is ahorizontal leg 288. Thevertical leg 286 is connected to an interior of the roof panelvertical wall 262 by any mechanical means known in the art, such as but not limited to the illustrated clinching of thevertical leg 286 to thevertical wall 262. For example, it should be appreciated that thevertical leg 286 can be welded to thevertical wall 262 or connected by use of self piercing rivets, bolts, etc. Thehorizontal leg 288 has a stepped configuration including an upper section 290 (i.e., a section closer to the upperhorizontal surface 150 of the roof panel 132) and alower section 292. Thelower section 292 of thehorizontal leg 288 is aligned with thedepressed section 250 and is adhered or bonded to the lowerhorizontal surface 264 of theroof panel 132 via the electricallynonconductive adhesive 230. This positions the connection between thefirst portion 280 of thefront bracket 164 and thevertical wall 262 of theroof panel 132 inwardly of the adhesive 230. Theupper section 290 extends outward beyond an end of the lower horizontal surface and is fixedly attached (e.g., welded) to thehorizontal wall 248 of theouter panel 240. The end portion of thewindshield 270 is adhesively bonded to theupper section 290 of thefront bracket 164. -
FIG. 4 depicts therear roof rail 120 connected to therearward end portion 142 of theroof panel 132 via therear bracket 166. Therear roof rail 120 includes anouter panel 300 and aninner panel 302. As is well known, a reinforcement (not shown) can be interposed between the outer and inner panels. Theouter panel 300 includes a flange structure havingvertical wall 306 and ahorizontal wall 308. Anend portion 310 of thehorizontal wall 308 can be angled; although, this is not required. Theinner panel 302 also includes a flange structure having ahorizontal wall 312 which is fixedly attached (e.g., welded) to the outer panelhorizontal wall 308. Therearward end portion 142 of theroof panel 132 includes arearward section 320 of theperipheral flange structure 152 having avertical wall 322 and a lower horizontal surface 324 (lower relative to the upper horizontal surface 150). - The
rear bracket 166 connects therear roof rail 120 to therearward section 320 of theperipheral flange structure 152 of the roof panel rearwardend portion 142. Therear bracket 166 includes afirst portion 330 and asecond portion 332. Thefirst portion 330 is fastened to thevertical wall 322. According to one aspect shown inFIG. 4 , thesecond portion 332 extends outwardly from the roof panel 132 a distance approximately equal to a distance thehorizontal wall 308 of theouter panel 300 extends outwardly from theroof panel 132. Therear bracket 166 is substantially L-shaped and thefirst portion 330 of therear bracket 166 is avertical leg 336 and thesecond portion 332 is ahorizontal leg 338. Thevertical leg 336 is connected to an interior of the roof panelvertical wall 322 by any mechanical means known in the art, such as but not limited to the illustrated clinching of thevertical leg 336 to thevertical wall 332. For example, it should be appreciated that thevertical leg 336 can be welded to thevertical wall 322 or connected by use of self piercing rivets, bolts, etc. Thehorizontal leg 338 has a stepped configuration including an upper section 340 (i.e., a section closer to the upperhorizontal surface 150 of the roof panel 132) and alower section 342. Thelower section 342 of thehorizontal leg 338 can be angled to match theangled end portion 310 of the outer panelhorizontal wall 308. According to the embodiment ofFIG. 4 , theupper section 340 is adhered or bonded to the lowerhorizontal surface 324 of theroof panel 132 via the electricallynonconductive adhesive 230. This positions the connection between thefirst portion 330 of therear bracket 166 and thevertical wall 322 of theroof panel 132 inwardly of the adhesive 230. Thelower section 342 extends outward beyond an end of the lowerhorizontal surface 324 and is fixedly attached (e.g., welded) to theend portion 310 of thehorizontal wall 308 of theouter panel 300. -
FIG. 5 shows another aspect of arear bracket 166′ for connecting arear roof rail 120′ to theperipheral flange structure 152 of theroof panel 132. Therear bracket 166′ includes afirst portion 330′ attached to thevertical wall 332 of theflange structure 152. Asecond portion 332′ of therear bracket 166′ is shorter in length than ahorizontal wall 308′ of anouter panel 308′ of therear roof rail 120′. This allows alower section 342′ of thesecond portion 332′ to be nested with and fixedly attached (e.g., welded) to the respectivehorizontal walls 308′, 312′ of theouter panel 300′ andinner panel 302′. Anupper section 340′ of thesecond portion 332′ is adhered or bonded to the lowerhorizontal surface 324 of theroof panel 132 via the electricallynonconductive adhesive 230. - It should be appreciated that the locations of the fastened connections (e.g., clinching) between the
first portion brackets roof panel 132 is generally dictated by the need for the strength of the attachment between thevehicle roof structure 102 andvehicle body 104 and more, closely-spaced, connections will promote stronger attachment. However, it should also be appreciated that distortion of theroof panel 132 can be minimized when fewer connections are employed, and thebrackets vehicle roof structure 102 and thevehicle body 104. In addition, each of thebrackets roof panel 132 of thevehicle roof structure 102 and thevehicle body 104 of approximately 4 mm to approximately 6 mm, and the adhesive 230 is provided in the spacing. As shown, this continuous spacing provided bybrackets roof panel 132 and thesecond portions brackets roof panel 132 to thevehicle body 104. According to one aspect, the continuous vertical spacing between theroof panel 132 and thevehicle body 104 is approximately 5 mm. This continuous vertical spacing maintained between thevehicle roof structure 102 andvehicle body 104 eliminates the concern for galvanic corrosion and also controls the flow and location of the e-coat on thevehicle assembly 100. It should also be appreciated that with the connection of thefirst portion respective bracket roof panel 132 being located inward of the adhesive 230, the adhesive 230 seals the connection of theroof panel 132 and each bracket from the intrusion of water/moisture and dirt debris to prevent galvanic corrosion between the dissimilar materials of theroof panel 132 andbrackets - As indicated above, rigidly attaching the aluminum-based alloy
vehicle roof structure 102 to the steel vehicle body 104 (i.e., vehicle components with dissimilar coefficients of thermal expansion—about 22.5×10−6 m/m K for aluminum and about 13×10−6 m/m K for steel) will generate thermal stresses when the temperature is raised or lowered. On heating, tensile stresses develop in the lower coefficient of thermal expansion material and compressive stresses develop in the material with the higher coefficient of thermal expansion. Thus, theroof panel 132 of the vehicle roof structure attached to thevehicle body 104 will be subjected to compressive thermal stresses with increase in temperature, the thermal stresses increasing generally in proportion to the temperature. - After assembly, but before attachment of closures such as doors or hoods, the
vehicle assembly 100 is washed and then painted. The paint must be cured by exposure to elevated temperatures, requiring that thevehicle assembly 102 to pass through at least one paint bake oven, subjecting the vehicle assembly to temperatures of up to 200° C. for a period of not less than 20 minutes. This temperature establishes the greatest compressive stress developed in the vehicle roof structure. Theroof panel 132, when subjected to compressive loads or stresses may deform, forming a buckle. If the buckling stress exceeds the yield stress of the metal of the roof panel, the buckle will be permanent and theroof panel 132 will not adopt its original configuration even after even after thevehicle assembly 100 exits the oven and cools. - The
brackets roof panel 132 relative to thevehicle body 104 when thevehicle assembly 100 is heated in the paint bake oven during the manufacture of the vehicle assembly. By way of example,FIG. 6A shows a pre-bake condition of thevehicle assembly 100.FIG. 6B shows thevehicle assembly 100 in a baking condition. As theroof panel 132 expands upwardly and outwardly, the adhesive 230 absorbs the expansion. As shown inFIG. 6C , theroof panel 132 returns to the pre-bake condition. Thus, the continuous spacing or gap provided by thebrackets aluminum roof panel 132 to distort during baking and curing of the adhesive (e.g., during an e-coat process) and allows shearing of the adhesive without the adhesive failing and without deformation of either theroof panel 132 or theside panel 112. Again, the adhesive 230 forms the primary connection between thesecond portions brackets roof panel 132, whereas the fastened connection (e.g., clinching) of thefirst portions roof panel 132 is more for positioning the roof panel and the brackets together prior to curing of the adhesive 230. The adhesive 230 provides flexibility during heating of the vehicle body to help absorb the stress associated with the different expansion rates of the dissimilar materials. And the depicted fastened (e.g. clinched) area is in a dry section because the adhesive 230 seals the connection of thebrackets roof panel 132 from moisture to prevent galvanic corrosion between the dissimilar materials. - As evident from the foregoing, to prevent distortion of the
vehicle roof structure 102 as described above, the present disclosure provides a method of assembling a vehicle including thevehicle body 104 formed of steel or a steel alloy and thevehicle roof structure 100 formed of aluminum or an aluminum-based alloy. The method comprises providing thevehicle body 102 including the pair of laterally spacedside panels front roof rail 118 and therear roof rail 120; providing thevehicle roof structure 102 including theroof panel 132 having theflange structure 152 provided at a peripheral edge portion; applying the adhesive 230 on thehorizontal surface flange structure 152 around an entire perimeter of theroof panel 132; positioning each of thebrackets flange structure 152 such that the adhesive 230 is between each bracket and the flange structure; positioning thevehicle roof structure 102 together with thebrackets vehicle body 104; fastening each of thebrackets vertical wall side brackets side panels front bracket 164 to thefront roof rail 118 and therear bracket 166 to therear roof rail 120; and heating thevehicle body 104 together with thevehicle roof structure 102 and thebrackets - The exemplary method further comprises providing a continuous vertical spacing between the
roof panel 132 and thevehicle body 104 of approximately 4 mm to approximately 6 mm by use of the side brackets, front bracket and rear bracket, and providing the adhesive 230 in the spacing; positioning the fastened connection between thebrackets flange structure 152 inwardly of the adhesive 230, and positioning the welded connection between thebrackets vehicle body 104 outwardly of the adhesive 230. The method further includes clinching the respectivevertical leg bracket vertical wall side panel brackets rear bracket 166, bonding theupper section horizontal leg horizontal surface flange structure 152, and for thefront bracket 164 bonding thelower section 292 of thehorizontal leg 288 to thehorizontal surface 264 of theflange structure 152. - While, for purposes of simplicity of explanation, the method has steps described as executing serially, it is to be understood and appreciated that the present disclosure is not limited by the illustrated order, and some steps could occur in different orders and/or concurrently with other steps from that shown and described herein.
- It will be appreciated that various of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Also that various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.
Claims (20)
Priority Applications (4)
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US14/174,103 US9114836B1 (en) | 2014-02-06 | 2014-02-06 | Vehicle roof structure |
JP2014230946A JP6601936B2 (en) | 2014-02-06 | 2014-11-13 | Vehicle roof structure |
CN201410772686.6A CN104828148B (en) | 2014-02-06 | 2014-12-12 | Vehicle assembly and the method for assembling vehicle |
DE102015201941.1A DE102015201941A1 (en) | 2014-02-06 | 2015-02-04 | Vehicle roof structure |
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US14/174,103 US9114836B1 (en) | 2014-02-06 | 2014-02-06 | Vehicle roof structure |
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US9114836B1 US9114836B1 (en) | 2015-08-25 |
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JP (1) | JP6601936B2 (en) |
CN (1) | CN104828148B (en) |
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Also Published As
Publication number | Publication date |
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JP6601936B2 (en) | 2019-11-06 |
JP2015147570A (en) | 2015-08-20 |
DE102015201941A1 (en) | 2015-08-20 |
CN104828148B (en) | 2018-07-17 |
US9114836B1 (en) | 2015-08-25 |
CN104828148A (en) | 2015-08-12 |
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