Vehicle roof bow

A vehicle includes first and second roof rails spaced from each other, and a forward member and rearward member connected to each other and each extending from the first roof rail to the second roof rail. The forward member includes a beam and a finger. The finger is on the first roof rail and extends from the beam away from the rearward member.

BACKGROUND

A vehicle may include two roof rails spaced from each other and each elongated in a vehicle-longitudinal direction. A plurality of roof bows may extend from one roof rail to the other roof rail. During a side impact of the vehicle, the roof bows may transmit energy from the roof rail on the impacted side to the other roof rail. The plurality roof bows are parallel to each other and are spaced from each other in the vehicle-longitudinal direction to increase the energy transmission between the roof rails during side impact.

A roof panel, which may be metal, may cover the plurality of roof bows to provide an exterior surface over the plurality of roof bows. The roof panel may extend from one roof rail to the other roof rail, and may extend across the plurality of roof bows from a windshield to a backlite of the vehicle and from the A-pillar to the C-pillar.

DETAILED DESCRIPTION

A vehicle includes first and second roof rails spaced from each other. A forward member and A rearward member are connected to each other and each extend from the first roof rail to the second roof rail. The forward member includes a beam and a finger. The finger is on the first roof rail and extends from the beam away from the rearward member.

The beam may extend from the finger toward the second roof rail.

The forward member may include another finger on the second roof rail extending from the beam away from the rearward member.

The rearward member may include a finger on the first roof rail extending away from the forward member. The rearward member may include another finger on the second roof rail and extending away from the forward member. The beam of the forward member may extend from one finger of the forward member to the other finger of the forward member, and the rearward member may include a beam extending from one finger of the rearward member to the other finger of the rearward member. The beam of the forward member and the beam of the rearward member are connected to each other at midpoints of the forward member and the rearward member. The beam of the forward member and the beam of the rearward member may be connected at a vehicle centerline. The beam of the forward member and the beam of the rearward member may be connected to each other at a connection point, and the beam of the forward member may extend from the connection point in a vehicle-forward direction toward the second roof rail, and the beam of the rearward member may extend from the connection point in a vehicle-rearward direction.

The rearward member may include a finger on the first roof rail and extending away from the forward member.

The forward and rearward members may fork toward the second roof rail.

The rearward member may include a beam that extends from the beam of the forward member toward the second roof rail.

The rearward member may include a beam connected to the beam of the forward member at a connection point, and the beam of the forward member may extend from the connection point in a vehicle-forward direction toward the second roof rail, and the beam of the rearward member may from the connection point in a vehicle-rearward direction.

The thickness of the finger may taper in a direction away from the rearward member along the roof rail.

The forward and rearward members may fork away from each other to the second roof rail, and a pillar may extend from the second rail between the forward and rearward members.

The forward and rearward members may be unitary.

The forward and rearward members may have a lattice structure.

With reference to the Figures, wherein like numerals indicate like parts throughout the several views, a vehicle10includes a first roof rail12and a second roof rail14spaced from each other. The roof rails extend horizontally. A roof bow16extends between the first roof rail12and the second roof rail14. As set forth further below, the roof bow16distributes forces from the first roof rail12to the second roof rail14during a side impact of the vehicle10. The numerical adjectives “first,” “second,” etc., are used merely as identifiers and are not intended to indicate order or importance.

The vehicle10may be any suitable type of automobile, e.g., a passenger or commercial automobile such as a sedan, a coupe, a truck, a sport utility vehicle, a crossover vehicle, a van, a minivan, a taxi, a bus, etc.

The vehicle10includes a body18. The body18may be of a unibody construction. As another example, the body18may be of a body-on-frame construction (also referred to as a cab-on-frame construction), i.e., the body18is a separate component from a frame and is supported on and affixed to the frame. Alternatively, the body18may have any suitable construction. The body18may be formed of any suitable material, for example, steel, aluminum, fiber-reinforced plastic, etc.

The body18includes a first side20and a second side22, i.e., a left side20and a right side22. The first side20and the second side22may be mirror images of each other or may be different from each other. The first side20and the second side22are spaced from each other along a lateral axis LAT of the vehicle10. The vehicle10includes a longitudinal axis LON, in other words a vehicle10centerline, perpendicular to the lateral axis LAT.

With reference toFIGS. 1-3, the body18includes the first roof rail12and the second roof rail14. The first roof rail12and the second roof rail14are each elongated along the longitudinal direction of the vehicle10and are spaced from each other along the lateral axis LAT of the vehicle10. The first roof rail12and the second roof rail14are fixed directly to another component of the body18, e.g., by welding, fusing, bolting, unitary construction, etc.

The body18may include a plurality of pillars24,26. The first side20and the second side22of the body18may both include pillars. The pillars24,26on the first side20and the second side22may be mirror images of each other. As an example, the pillars24,26may be positioned as A-pillars24, B-pillars26, and C-pillars, etc. In such an example, the pillars may be positioned along the longitudinal axis LON with the A-pillar24in a vehicle-forward direction VF with respect to the B-pillar26, the B-pillar26in a vehicle-forward direction VF with the respect to the C-pillar, etc. In other words, in such an example including the A-pillar24, B-pillar26, and C-pillar, the B-pillar26is between the A-pillar24and the C-pillar. The pillars are fixed directly to another component of the body18, e.g., by welding, fusing, bolting, unitary construction, etc.

The pillars support the first roof rail12and the second roof rail14. Specifically, the body18includes floor rails30, and the pillars may extend from the roof rails to the floor rails30, respectively.

The body18includes door openings32. As an example, the first side20and the second side22may each include one door opening32, as shown in the Figures, or may include more than one door openings32. The pillars may be disposed on opposite sides of one door opening32. In other words, the pillars may define at least a portion of each door opening32. Additionally, the roof rails and floor rails30may define at least a portion of each door opening32. As an example, as shown in the Figures, one door opening32may be defined by the A-pillar24and the B-pillar26. As another example, another door opening32may be defined by the B-pillar26and the C-pillar. With reference toFIG. 1, the body18includes a roof panel34. The roof panel34may extend from the first roof rail12to the second roof rail14. In such an example, the roof panel34may be connected to the first roof rail12and the second roof rail14in any suitable fashion, e.g., welding, adhesive, etc. The roof panel34may be elongated in the along the lateral axis LAT of the vehicle10, e.g., from the first roof rail12to the second roof rail14. The roof panel34may include an exterior surface that is a class-A surface, i.e., i.e., a surface specifically manufactured to have a high-quality, finished aesthetic appearance free of blemishes. The roof panel34may be any suitable material, for example, metal (e.g., aluminum, steel, etc.), polymeric (e.g., fiber reinforced plastic, sheet-molded composite), etc.

The vehicle10includes a windshield36and a backlite38. The windshield36and the backlite38are transparent. The windshield36and the backlite38, for example, may be glass.

The windshield36and/or the backlite38may be connected to the roof panel34. For example, the windshield36and/or the backlite38may be adhered to the roof panel34with adhesive40, as shown inFIG. 7. In such a configuration, the roof panel34may include ledges that receive the windshield36and the backlite38, respectively, and the windshield36and backlite38may be adhered to the ledges, as shown inFIG. 7.

As an example, shown inFIGS. 1 and 7, the windshield36and the backlite38may both be connected to the roof panel34, for example, both may be adhered to the roof panel34as shown inFIG. 7. In this configuration, the roof panel34extends from the windshield36to the backlite38.

The connection of both the windshield36and the backlite38to the roof panel34creates a panoramic view for occupants of the vehicle10. In other words, this configuration allows for the roof panel34to consume a small footprint above an occupant cabin42of the vehicle10, which allows for a greater overhead view through the windshield36and the backlite38. As shown inFIGS. 1-3, the windshield36and the backlite38may both extend over occupant headspace, i.e., the space in the occupant cabin42occupied by an adult occupant seated in an upright position, to create the panoramic view. Specifically, the windshield36may extend over occupant headspace above a front row of seats44, shown in phantom inFIG. 3, and the backlite38may extend over occupant headspace above a rear row of seats46, shown in phantom inFIG. 3.

As shown inFIGS. 2 and 7, the vehicle10includes a headliner48. The headliner48extends along the roof panel34in the occupant cabin42. Specifically, the headliner48may extend from the first roof rail12to the second roof rail14, and may extend from the windshield36to the backlite38. The headliner48may be connected to the first roof rail12, the second roof rail14, and/or the roof panel34.

As shown inFIG. 7, the roof bow16may be between the headliner48and the roof panel34. The headliner48may provide a class-A surface facing the occupant cabin42. The headliner48may be plastic, foam, leather, vinyl, etc. and combinations thereof.

The roof bow16is elongated along the lateral axis LAT. The roof bow16connects the first roof rail12to the second roof rail14. For example, as shown in the Figures, the roof bow16may extend from the first roof rail12to the second roof rail14. The roof bow16may be fixed directly to the body18, e.g., the first roof rail12and the second roof rail14. For example, the roof bow16may be fixed directly to the body18by welding, fusing, bolting, unitary construction, etc. As another example, the roof bow16may be fixed to the body18by an intermediate component in such a way that force may be transmitted by the roof bow16from one roof rail12,14, to the other roof rail12,14.

The roof bow16may include a forward member50and a rearward member52. Both the forward member50and the rearward member52may connect the first roof rail12to the second roof rail14. The forward member50and rearward member52each extend from the first roof rail12to the second roof rail14. For example, as shown in the Figures, both the forward member50and the rearward member52may extend from the first roof rail12to the second roof rail14. Both the forward member50and the rearward member52are fixed directly to the body18, e.g., the first roof rail12and the second roof rail14. For example, both the forward member50and the rearward member52may be fixed directly to the body18by welding, fusing, bolting, unitary construction, etc.

The roof bow16may include a plurality of beams54. As shown in the figures, the forward member50and the rearward member52may each include one beam54. The beam54of the rearward member52may be a mirror image of the beam54of the forward member50.

The forward member50and the rearward member52are connected to each other. In one example, the forward member50and the rearward member52, e.g., the beam54of the forward member50and the beam54of the rearward member52, may be connected to each other at midpoints56of the forward member50and the rearward member52. The forward member50and the rearward member52, e.g., the beam54of the forward member50and the beam54of the rearward member52, may be connected at a vehicle centerline, i.e., a longitudinal centerline of the vehicle10. The midpoints56of the forward member50and the rearward member52may be at the vehicle centerline.

The forward member50and the rearward member52may be connected to each other in any suitable fashion. As one example shown inFIG. 4, the forward member50and rearward member52are unitary, i.e., the combination of the forward member50and the rearward member52is a single, uniform piece of material with no seams, joints, fasteners, or adhesives holding it together. In such an example, the forward member50and the rearward member52may be formed as a single unit by additive manufacturing. In the alternative to being unitary, the forward member50and the rearward member52may be separate components, as shown inFIG. 5, i.e., separately formed and subsequently joined. In such an example, the forward member50and the rearward member52may be joined by a fastener, adhesive, welding, fusing, etc.

The forward member50and rearward member52, e.g., the beams54, fork relative to each other. For example, the forward member50and rearward member52may fork away from each other toward the first roof rail12. As another example, the forward member50and rearward member52may fork away from each other toward the second roof rail14. In the configuration shown in the Figures, the forward member50and rearward member52may be arranged in an X-shape, i.e., the roof bow16is X-shaped.

The forking of the forward member50and the rearward member52distributes the forces during a side impact. As an example, during a side impact at the first side20, the roof bow16distributes force to the second roof rail14. Similarly, during a side impact at the second side22, the roof bow16distributes force to the first roof rail12. Specifically, since the forward member50and the rearward member52fork, the forces of the impact on the first side20are transmitted to the forward member50and/or the rearward member52at the first roof rail12and are distributed to both the forward member50and the rearward member52at the second roof rail14to reduce loading concentration at the second roof rail14. Similarly, the loading concentration at the first roof rail12is reduced during an impact on the second side22.

The B-pillars26may be disposed on the roof beams54, respectively, between the forward member50and the rearward member52along the longitudinal axis LON. In other words, the forward member50and rearward member52are on opposite sides of each B-pillar26.

The roof bow16may include a plurality of fingers58. For example, the forward member50may include one or more fingers58and the rearward member52may include one or more fingers58. In the example shown in the Figures, the forward member50includes two fingers58, i.e., one at the first roof rail12and another at the second roof rail14, and the rearward member52includes two fingers58, i.e., one at the first roof rail12and another at the second roof rail14.

The fingers58may assist in distributing the force of the side impact. Specifically, when loads are transmitted to the fingers58, the fingers58transmit the load to the respective roof rail. The extension of the fingers58along the longitudinal axis LON reduces the loading concentration at the respective roof rail. Specifically, the finger58on the forward member50extends from the beam54in a vehicle-forward direction VF to transmit loads in the vehicle-forward direction VF, and the finger58on the rearward member52extends from the beam54in a vehicle-rearward direction VR to transmit loads in the vehicle-rearward direction VR.

The fingers58may be on the roof rails, and the roof rails may support the fingers58. The fingers58are connected to the roof rails. For example, the fingers58may be fixed to the roof rails by welding, fusing, bolting, unitary construction, etc. The fingers58may be fixed to the roof rails directly, or indirectly through an intermediate component.

With reference toFIGS. 2 and 3, one finger58of the forward member50is on the first roof rail12and extends from the beam54away from the rearward member52along the longitudinal axis LON in a vehicle-forward direction VF. The other finger58of the forward member50is on the second roof rail14and extends from the beam54away from the rearward member52along the longitudinal axis LON in a vehicle-forward direction VF.

With continued reference toFIGS. 2 and 3, one of the fingers58of the rearward member52is on the first roof rail12and extends from the beam54away from the forward member50along the longitudinal axis LON in a vehicle-rearward direction VR. The other finger58of the rearward member52is on the second roof rail14and extends from the beam54away from the forward member50along the longitudinal axis LON in a vehicle-rearward direction VR.

With reference toFIGS. 2 and 3, the fingers58of the forward member50extend from the beam54of the forward member50. The beam54of the forward member50extends from the finger58on the first roof rail12toward the second roof rail14, and the beam54of the forward member50extends from the finger58on the second roof rail14toward the first roof rail12. Specifically, the beam54of the forward member50may extend from one finger58of the forward member50to the other finger58of the forward member50.

With reference toFIGS. 2 and 3, the fingers58of the rearward member52extend from the beam54of the rearward member52. The beam54of the rearward member52extends from the finger58on the first roof rail12toward the second roof rail14, and the beam54of the rearward member52extends from the finger58on the second roof rail14toward the first roof rail12. Specifically, the beam54of the rearward member52may extend from one finger58of the rearward member52to the other finger58of the rearward member52.

With reference toFIG. 6, the thickness T of the fingers58may taper. For example, the thickness T of the fingers58extending from the forward member50may taper in a direction away from the rearward member52along the roof rail. As another example, the thickness T of the fingers58extending from the rearward member52may taper in a direction away from the forward member50along the roof rail. The tapering of the fingers58determines the load distribution and concentration at the respective rail. The length and degree of tapering may be designed to manage the distribution of loads to the respective roof rail as desired.

As one example, the roof bow16may have a lattice structure. In other words, the material, i.e., at a macroscopic level, of the roof bow16may be arranged in a regular, repeated, three-dimensional arrangement pattern of cells. For example, this pattern of cells may have a honeycomb shape. The pattern of cells has voids. As an example, the voids may have a diameter of 5-100 cm. For illustrative purposes the lattice structure62is shown only inFIGS. 4 and 5. InFIGS. 4 and 5, the entire roof bow16has the lattice structure. Alternatively, portions of the roof bow16may have the lattice structure, and other portions of the roof bow16may have other configurations, e.g., solid, bio-derived shape, etc. As another example, the roof bow16may have any suitable configuration such as any combination of lattice structure, bio-derived shape, solid, etc. The structure, shape, thickness, etc., of the roof bow16may be customized to provide force absorption and transmission needed for a specific vehicle design.

The roof bow16may be any suitable material, e.g., metal (e.g., aluminum, steel, etc.), polymeric (e.g., fiber reinforced plastic, sheet-molded composite), etc. The material type of the roof bow16may be uniform throughout the roof bow16. Alternatively, components of the roof bow16, e.g., the forward member50and the rearward member52, may be different.

During a vehicle10impact, e.g., a side impact, the roof bow16distributes the force of the impact to assist in absorbing the energy of the vehicle10impact and reducing intrusion into the occupant cabin42. As set forth above, since the roof bow16extends from the first roof rail12to the second roof rail14, the roof bow16reinforces the body18. For example, when the first side20is impacted, the roof bow16distributes the forces to the second side22such that the second side22reinforces the impacted first side20. Specifically, since the forward member50and the rearward member52fork, the forces of the impact on the first side20are transmitted to the forward member50and/or the rearward member52at the first roof rail12and are distributed to both the forward member50and the rearward member52at the second roof rail14to reduce loading concentration at the second roof rail14. The load distribution by the forward and rearward members52increases the strength of the body18during side impact, while allowing for the panoramic view described above.