Vehicle roof fitting with integrated RF transparent for electronic module integration

Abstract

The invention relates to a vehicle roof assembly with integrated RF transparency for electronic module integration. An example vehicle roof assembly is disclosed that features an outer roof panel made of a radio frequency (RF) transparent polymeric material, such as polycarbonate (PC), acrylonitrile-butadiene-styrene (ABS), or acrylonitrile-styrene-acrylate (ASA). In some examples, the assembly enables direct integration of overhead electrical modules and components, including antennas, into a roof construction, facilitating clear communication with external devices and satellites. The design employs a thin film effect for enhancing protection of occupants during a collision and using an integrated foam material between the outer roof and the inner ceiling to improve thermal and acoustic insulation. By pre-filling electrical components on the roof, the assembly process is simplified, individual unit installation is allowed, and it is possible to achieve full automation in the assembly line. The polymeric structure of the roof also provides enhanced sagging resistance, color selection, and inherent corrosion resistance, and complies with safety standards such as the Head Injury Standard (HIC) value.

Description

Technical Field

[0001] This disclosure generally relates to vehicle construction, and more specifically, to an integrated roof fitting for a vehicle that incorporates radio frequency (RF) transparent materials to enable the integration of roof-mounted electrical modules and components. Background Technology

[0002] Traditional vehicle roof construction typically involves using metal or glass materials that provide structural integrity and protect the vehicle from environmental factors. However, these materials present limitations when it comes to integrating modern vehicle technologies, especially those requiring radio frequency (RF) transmission and reception. Metal roofs, while providing structural rigidity, act as a barrier to RF signals, necessitating the external placement of antennas and other communication equipment. On the other hand, glass roofs allow for RF transparency, but present challenges in integrating electronic components without compromising aesthetic appeal and visibility.

[0003] Furthermore, assembling electronic modules and components in vehicles with conventional roofs typically involves a complex and time-consuming process involving multiple connections, which can present ergonomic challenges for assembly workers. In particular, roof-mounted installations are labor-intensive and limit opportunities for assembly line automation. Additionally, traditional roof structures may not adequately meet requirements for heat and sound insulation, occupant protection, and compliance with safety regulations such as head impact standards. Summary of the Invention

[0004] Some examples of this disclosure provide a vehicle roof fitting that utilizes a radio frequency (RF) transparent polymer material, enabling direct integration of roof-mounted electrical modules and components into the roof structure. This approach overcomes the limitations of traditional metal and glass roofs by allowing RF signals to pass through the roof material, thereby facilitating the integration of electronic systems and antennas that require unobstructed paths to communicate with external devices and satellites.

[0005] Some examples of vehicle roof fittings in this article include high-strength polymer blends such as polycarbonate (PC), acrylonitrile-butadiene-styrene (ABS), or acrylonitrile-styrene-acrylate (ASA), which are selected for their RF transparency and structural properties. In some examples, these materials provide adequate strength for crashworthiness, stiffness for noise, vibration, and harshness (NVH) control, and compliance with head-on collision regulations. In some examples, the combination of these polymers also allows for an opaque roof, thereby reducing solar radiation transmission, lowering the heat load on the passenger compartment, and improving the thermal comfort of vehicle occupants.

[0006] Some examples demonstrate the ability to pre-fill selected electrical components into the roof structure, which are then installed as a unit during vehicle assembly. This can improve the efficiency of assembly workers and reduce assembly time and workload. In some examples, vehicle roof assemblies can be pre-assembled on a horizontal surface, eliminating the need for a roof-mounted process and enabling full automation of roof subsystem assembly.

[0007] Some examples also offer enhanced thermal and sound insulation by using foam between the external polymer roof and the internal roof. Polymer roof construction provides superior sound insulation properties to reduce airborne noise within the vehicle cabin.

[0008] In traditional vehicle design, the roof is typically a separate component from the roof and is designed to compress during a collision to absorb energy. This compression is the primary means by which the roof mitigates impact forces to protect the occupants' heads, and a certain thickness or space is required between the roof and the roof to provide sufficient cushioning.

[0009] In contrast, some examples in this paper utilize polymer roof constructions exhibiting a "film effect." The film effect of polymer roofs contributes to occupant crash protection by allowing the roof (e.g., an external RF transparent polymer roof panel) and the head dome (e.g., defined within an internal substrate assembly) to deflect together during a stroke (or movement), unlike conventional roofs that rely solely on compression. In other words, in the context of a vehicle roof and head dome, the term "stroke together during a deflection" refers to how the roof material and the internal roof (often referred to as the head dome) react to a collision, such as when an occupant's head contacts the roof during a collision. In some examples, the external RF transparent polymer roof panel and the internal substrate assembly can stroke together during a collision.

[0010] The polymer material of the roof itself possesses a degree of flexibility, allowing it to deflect or bend to some extent. In the event of a collision, the polymer roof and headliner can move together as a single unit, bending inward to absorb impact energy. This deflection of the outer roof substrate, combined with the headliner, provides an additional energy absorption mechanism. One advantage of this design is that, because the roof material itself contributes to collision protection, it reduces the need for a thick buffer layer between the canopy and the roof. This allows for a thinner, single-piece roof structure, enabling greater headroom inside the vehicle and potentially reducing the weight of the roof fittings. The disclosed example still complies with safety standards, such as the Head Injury Standard (HIC) values ​​specified by regulations governing upper interior head impact protection, such as Federal Motor Vehicle Safety Standard (FMVSS) 201U.

[0011] In some examples, when an object (such as an occupant's head) collides with the roof, the membrane effect allows the polymer material to deflect, absorbing and dissipating energy over a larger area. This reduces the force transmitted to the object, and in this case, to the occupant's head, potentially reducing injury. The compliance of polymer materials means that they can deform to a certain extent without breaking or fracturing. This compliance helps absorb collision energy and provides a cushioning effect. Traditional vehicle roofs may require thicker, stiffer materials to provide structural integrity and collision protection. The membrane effect of polymer roofs allows for thinner structures that still meet safety standards because the material itself can absorb energy. Vehicles must meet safety standards such as the Federal Motor Vehicle Safety Standard (FMVSS) 201U, which specifies standards for upper interior head impact protection. The membrane effect of polymer roofs helps meet these standards by allowing the roof and canopy to travel together or move in unison to effectively absorb collision energy. In some examples, the membrane effect can provide greater design flexibility because the roof can be designed with different degrees of flexibility and stiffness in different areas, optimizing both its collision protection and overall vehicle performance. In some examples, the thin-film effect of polymer roof construction enhances crash protection by allowing the roof to bend and absorb energy during a collision, which can reduce the severity of occupant injuries and provide vehicle manufacturers with more design options.

[0012] Some of the example fittings for the roof construction disclosed in this article also benefit from partial reduction, as rib features and shapes can be molded into polymer geometry, eliminating the need for additional metal roof crossbeams. Polymer materials offer superior dent resistance, better processability through molding reference pins, sharper feature formability, a wide range of color options, and inherent corrosion resistance.

[0013] Some examples attempt to provide a vehicle roof accessory that not only improves the integration and performance of in-vehicle electronic systems, but also enhances manufacturing efficiency, vehicle safety, and passenger comfort. Attached Figure Description

[0014] In all the accompanying drawings, reference numerals may be used repeatedly to indicate the correspondence between reference elements. The drawings are provided to illustrate examples of the subjects described herein, not to limit their scope.

[0015] Figure 1 It is a perspective partial cross-sectional view of a vehicle roof fitting installed on a vehicle, based on some examples.

[0016] Figure 2AThis is a perspective view of an example antenna module and mounting housing for integration with an external RF transparent polymer roof panel, illustrating example pre-filled electrical components and antenna.

[0017] Figure 2B yes Figure 2A A side view of an example antenna module and its mounting housing.

[0018] Figure 3 This is a component diagram illustrating example electrical components and their connections to vehicle systems, including cabin radar and onboard computer, based on some examples.

[0019] Figure 4A This is an exploded view of the roof assembly kit for the example vehicle, showing the external RF transparent polymer roof panel and associated individual components such as the grounding plate, mounting brackets, and reference blocks.

[0020] Figure 4B This is an exploded view of an example second vehicle roof fitting kit, showing example components of an internal substrate fitting according to some examples, including a wrapped polymer substrate and an insulating layer.

[0021] Figure 4C The illustration shows an example first adhesive application pattern for bonding a wrapped polymer substrate to an isolation layer.

[0022] Figure 5 This is a flowchart of example operations from some examples of methods for forming the roof of a vehicle.

[0023] Figure 6 Enlarged views are provided of an example first vehicle roof assembly, an example antenna module and mounting housing, an example closeout panel, and an example complete vehicle roof assembly, including an example adhesive application pattern for bonding the assembly to the vehicle.

[0024] Figure 7 It is a table listing example specifications for various components of the roof fittings of example vehicles, based on some examples.

[0025] Figure 8 It is a flowchart illustrating the process of assembling the roof of a vehicle based on some examples. Detailed Implementation

[0026] Some examples in this article provide a vehicle roof mount in which a radio frequency (RF) transparent polymer is used as the primary material for the roof structure. This material choice facilitates the integration and consolidation of electrical components that interface with both the interior and exterior of the vehicle cabin. The roof mount is designed to house desired or required electrical components and is installed as a single unit during the vehicle assembly process. In some examples, this approach can provide manufacturing efficiency, and in some cases, eliminates the need for roof-mounted interior mounts, thus providing ergonomic benefits for assembly line workers.

[0027] The roof structure utilizes high-strength polymer blends, including but not limited to polycarbonate (PC), acrylonitrile-butadiene-styrene (ABS), and acrylonitrile-styrene-acrylate (ASA). These materials are chosen because of their ability to meet roof structure requirements, such as crashworthiness, typically quantified by strength; noise, vibration, and harshness (NVH), typically quantified by stiffness; and compliance with head impact regulations, typically quantified by energy absorption capacity. In some examples, the opacity of the roof is used to prevent or reduce solar radiation penetration into the passenger compartment, thereby reducing heat load and improving occupant thermal comfort. Secondly, the opacity of the roof allows for the use of foam between the external polymer roof and the internal headliner to further enhance insulation.

[0028] In some examples, the RF transparency of the chosen polymer can be important for the integration of various electronic components and antennas, reducing the total number of endpoints and electrical connections within the vehicle. Electrical modules, typically including components for in-vehicle infotainment systems and external RF communication devices, are conventionally encapsulated in an isolated space between the external roof and the interior headliner. These modules require a field of view (FOV) unobstructed by RF-opaque materials, thus necessitating the use of frequency-transparent materials to surround the substrate and panel.

[0029] By employing polymer blends, some examples demonstrate the ability to transmit RF from all modules to other communication devices inside and outside the satellite and vehicle. This integration into a single electronic module results in reduced parts, connector consolidation, and enhanced performance due to the coordinated positioning of processing / computing capabilities and the reduction in cable length and connector losses.

[0030] In addition to thermal benefits, polymer roof construction with an intermediate foam layer can provide enhanced sound insulation and sound absorption properties. Examples show a significant reduction in airborne noise generated by wind and road conditions within the vehicle cabin.

[0031] Occupant crash protection is also a feature in some examples. Compared to conventional glass roofs, the thin-film effect of polymer roofs allows the roof and head dome to stroke together via deflection of the outer roof substrate. This is due to the low modulus of the polymer material, which reduces the cross-section between the canopy and the roof to accommodate the head dome stroke, unlike conventional canopies that require only compression mechanisms and require greater thickness.

[0032] In some examples, the assembly process is simplified by integrating electrical components into larger modules and reducing the number of electrical interconnects, resulting in a 3 to 5-fold reduction in assembly workload and time. Factory ergonomics are improved because roof fittings can be pre-assembled on an inverted horizontal plane, allowing for a layered installation sequence without the need for a top-mounted installation process. The design also facilitates factory automation by enabling fully automated layered assembly of the roof subsystem.

[0033] The polymer roof design incorporates molded rib features and forms, eliminating the need for welded metal roof crossbeams used in traditional metal roof constructions. This results in reduced sections and superior dent resistance compared to the brittleness of glass roofs. The ability to mold reference pins directly into the panels ensures optimal process conditions between panels, independent of assembly fasteners. Polymer materials also offer greater formability compared to traditional stamping processes, allowing for smaller radii and sharper features or facets. Furthermore, polymer roofs allow for colorants in the resin, eliminating the need for post-treatment painting, and their inherent corrosion resistance reduces the need for additional corrosion protection and post-treatment.

[0034] Some examples also address limitations found in conventional vehicle designs, which typically feature "shark fin" external antennas for LTE and GNSS communications mounted on a metal roof. The metal roof, usually constructed of aluminum or steel, serves as the ground plane for the antenna, contributing to increased structural rigidity and stiffness of the vehicle. However, this metal layer also acts as an RF barrier, preventing the integration of internally oriented wireless modules due to its RF opacity. Some examples of polymer roof mounts disclosed herein attempt to overcome this limitation by providing an RF-transparent environment, allowing the integration of both internal and external communication modules without the interference issues associated with a metal substrate.

[0035] Figure 1An example vehicle roof mount 102 is shown mounted on a vehicle roof. The vehicle roof is generally shown as roof 120. The illustrated portion of vehicle roof mount 102 is mounted near and at least partially supported by the B-pillar 112 of the vehicle. Vehicle roof mount 102 broadly includes at least two vehicle roof sub-mounts, which will be further described below in conjunction with the method of assembling vehicle roof mount 102. A first vehicle roof sub-mount includes an external RF transparent polymer roof panel 104, which in some examples is pre-filled for installation into vehicle roof mount 102, wherein one or more electrical components are generally shown as electrical components 116. The more specific type and configuration of electrical components 116 are described below.

[0036] The vehicle roof fitting 102 also includes an inner substrate fitting 106. In some examples, the inner substrate fitting 106 includes a wrapped polymer substrate 114, one or more insulating layers 108 (e.g., including honeycomb or fibrous foam), and a canopy 110 (or trim). In some examples, the inner substrate fitting 106 defines a shaped free region or zone referred to as a head dome 118. This region accommodates the head of a vehicle occupant. In some examples, the head dome 118 of the inner substrate fitting 106 and the outer RF transparent polymer roof panel 104 can travel together during a collision thanks to the film effect further described above.

[0037] Figures 2A to 2B This illustrates the installation of the external RF transparent polymer roof panel 104 onto... Figure 1 Before the vehicle roof fitting 102, it can be pre-filled or pre-installed. Figure 1 Examples of one or more electrical components 116 in the external RF transparent polymer roof panel 104. The electrical components 116 may be housed within or located on the antenna module and mounting housing 222. The antenna module and mounting housing 222 may be provided with or include a closed panel 602, as described below. Figure 6 This can be seen more clearly in the image. The antenna module and mounting housing 222 can accommodate and support one or more electrical components 116, such as satellite communication components 224, satellite antenna 202, LTE components 232, LTE antenna 204, speaker 228, fan 218, fan intake duct 226, connectivity card 214, processor 220, Bluetooth Low Energy component 206, microphone 216, map light 212, and switch 230. For example, switch 230 may include a manually operated switch to operate the vehicle's emergency lights.

[0038] Satellite communication component 224 can communicate with external device 208, such as a GNSS satellite, using satellite antenna 202. LTE antenna 204 can communicate with external device 210, such as a 3G, 4G, or 5G LTE network. Other antennas are also possible, such as antennas for establishing Wi-Fi and / or Bluetooth connections for one or more electrical components 116.

[0039] from Figure 2B As can be seen in the view, in some examples, Figure 1 The outer surface of the external RF transparent polymer roof panel 104 has no metal substrate, film, or coating. In some examples, the outer surfaces of the satellite antenna 202 and LTE antenna 204 integrated within the external RF transparent polymer roof panel also lack metal substrates, films, or coatings. This device provides a clear and unobstructed field of view for these components to communicate with their respective external devices, satellites, networks, etc.

[0040] As described above, some examples in this paper attempt to address limitations in conventional vehicle designs, which typically feature "shark fin" external antennas for LTE and GNSS communications mounted on a metal roof. The metal roof, usually constructed of aluminum or steel, serves as the ground plane for the antenna, contributing to increased structural rigidity and stiffness of the vehicle. However, this metal layer also acts as an RF barrier, preventing the integration of internally-facing wireless modules due to its RF opacity. Some examples of polymer roof mounts disclosed herein attempt to overcome this limitation by providing an RF-transparent environment, allowing the integration of both internal and external communication modules without the interference issues associated with the metal substrate.

[0041] Figure 3 Example component diagrams are shown of some electrical components in example electrical components 116 of example vehicle roof mount 102. Electrical components 116 shown include a microphone 216, a switch 230, a satellite antenna 202, a speaker 228, a Bluetooth Low Energy component 312, one or more LTE antennas 204, a first Wi-Fi / Bluetooth antenna 314, a second Wi-Fi / Bluetooth antenna 316, and a processor 220 (referred to in the view as the applicant-submitted processor).

[0042] Vehicle roof fittings 102 ( Figure 3 An electrical component 116 (referred to as a smart roof) electrically connects the cabin radar 302 and the vehicle computer 304. The cabin radar 302 is electrically connected to or may include a set of sensors 308 to detect occupants or unauthorized entry into the vehicle. An authentication module 306 can authenticate vehicle occupants based on one or more personal data or device identification data (e.g., device ID). The connectivity module 310 can check... Figure 2AThe connection status of one or more of the connectivity cards 214, the processor 220 of FIG2, the satellite communication component 224 of FIG2, the satellite antenna 202, the LTE component 232, the LTE antenna 204 and / or other electrical components 116.

[0043] As mentioned above Figure 1 In some examples, the vehicle roof fitting 102 generally comprises at least two vehicle roof fittings. Various components used to form or assemble the vehicle roof fitting may be provided as one or more kits.

[0044] refer to Figure 4A The illustration shows example components from a first vehicle roof fitting or partial kit. In the example shown, these components include an external RF transparent polymer roof panel 104, and a set of other smaller components, in... Figure 5 This is referred to as single-piece part 502. Single-piece part 502 may include one or more ground planes 402, one or more mounting brackets 404, one or more seals 408, and one or more antennas 406. Antenna 406 may include one or more satellite antennas 202, and / or one or more LTE antennas 204. Figure 2A and Figure 2B Other antennas are also possible. In some examples, the single-piece part 502 also includes one or more wiring harnesses 410 and one or more reference blocks 412. The first vehicle roof assembly 504 is assembled in Figure 5 The figure is shown in the diagram, and its assembly method is further described below with reference to the figure.

[0045] refer to Figure 4B The illustration shows example components of a second vehicle roof fitting or partial kit. These example components include a wrapped polymer substrate 114 and one or more insulating layers 108 (each in...). Figure 1 (See image). These components can be bonded together with adhesive to form the internal substrate assembly 106 (in... Figure 1 This can also be seen in the text, and in Figure 5 The second vehicle roof assembly 506 is shown in an assembled form. Figure 6 The internal substrate assembly 106 constitutes, or at least includes, the internal substrate assembly 106. Figure 6 Internal substrate assembly 106.

[0046] In the construction and / or configuration of vehicle roof fittings, some examples include materials used for the internal substrate fitting 106 to optimize thermal insulation and noise suppression. Some materials may be selected based on their insulation properties and sound absorption characteristics, as well as their suitability for integration into the vehicle roof fitting.

[0047] Polyurethane foam possesses excellent thermal insulation and sound absorption properties. Its versatility allows it to be molded and fitted into complex roof geometries, providing a customized fit that enhances its insulation and noise suppression performance. Another suitable material is polyethylene foam, which is lightweight and has good thermal insulation properties. It also contributes to sound absorption and can be effectively used in vehicle roof fittings where weight reduction is a priority. For better sound absorption, melamine foam can be used in vehicle roof fittings. While melamine foam is primarily known for its sound-absorbing properties, it also provides good thermal insulation, making it a dual-purpose material in the automotive field. Mass-loaded ethylene (MLV) is a relatively high-density material that can act as an effective barrier against airborne noise. When incorporated into vehicle roof fittings, MLV can significantly reduce the transmission of external noise into the cabin, improving the overall acoustic comfort of occupants. Closed-cell foam is another material that provides excellent thermal insulation and moisture protection. This moisture protection is particularly effective in preventing condensation within vehicle roof fittings, thus maintaining insulation efficiency over time.

[0048] In some examples of the internal substrate assembly 106 addressing thermal and acoustic challenges, thermally insulated acoustic panels can be employed. These panels typically include a sound-absorbing layer bonded to an insulation layer, which is usually made of materials such as polypropylene or polyester fibers. In applications where space is extremely limited, aerogel insulators can be used due to their excellent thermal insulation properties in a very thin form factor. While aerogel is a more expensive option, its performance justifies the cost in certain design scenarios.

[0049] Textile-based insulation materials made from nonwoven fabrics offer a lightweight and versatile option for both thermal and acoustic insulation. These textiles can be treated with flame retardants to ensure compliance with automotive safety standards, making them a safe choice for vehicle roof fittings. Finally, damping compounds, acting as viscoelastic materials, can be applied to the substrate within the vehicle roof fitting to reduce vibration and noise transmission. These compounds are particularly effective in suppressing resonant frequencies that cause noise within the cabin. Examples of factors to consider when selecting materials for interior substrate fittings include weight, flammability, ease of installation, environmental resistance, and compliance with automotive safety standards. In some examples, combinations of these materials achieve an optimal balance between thermal insulation, noise reduction, and overall vehicle performance.

[0050] Figure 4C An example first adhesive application pattern 414 is shown for bonding the encapsulated polymer substrate 114 and the insulating layer 108 together to form the internal substrate assembly 106 of the second vehicle roof assembly 506. Other adhesive patterns are also possible.

[0051] Some of the examples disclosed in this article include methods. References Figure 5 The following describes example operations in the method of forming the roof. Although the described flow may be presented as a sequential process, many operations can be performed in parallel or simultaneously. Furthermore, the order of operations can be rearranged. When the operations of a process are completed, the process terminates. A process can correspond to a method, a program, an algorithm, etc. The operations of a method can be performed in whole or in part, can be combined with some or all of the operations in other methods, and can be performed by any number of different systems, such as the system described herein or any part thereof, such as a processor included in any system.

[0052] In operation 508, the external RF transparent polymer roof panel 104 and the single-piece portion 502 are mechanically assembled or bonded together to form the assembled first vehicle roof assembly 504. In operation 510, one or more adhesive receiving surfaces (surface preparation) of the second vehicle roof assembly 506 are prepared and adhesive is applied thereto. The second vehicle roof assembly 506 may have been previously referenced as described above. Figure 4B The assembly is described. In operation 512, the first vehicle roof sub-assembly 504 and the second vehicle roof sub-assembly 506 are positioned together or otherwise aligned (partially) and bonded together to form a complete external sub-assembly and internal sub-assembly 514. The aforementioned operations can be performed as part of a general vehicle assembly performed, for example, by a vehicle manufacturer or by a supplier of the complete external and internal sub-assembly 514. The following operations can be performed as part of a general vehicle assembly performed by a vehicle manufacturer.

[0053] For ease of assembly, in operation 516, the complete external and internal subassemblies 514 can be inverted, such as in a vehicle assembly line at a vehicle manufacturing plant. In operation 518, the antenna module and mounting housing 222, as well as the enclosure panel 602, are mechanically assembled to the complete external and internal subassemblies 514. When the antenna module and mounting housing 222, as well as the enclosure panel 602, are mechanically assembled to the complete external and internal subassemblies 514 to form the complete vehicle roof assembly 102, the complete external and internal subassemblies 514 may or may not be inverted. In operation 520, one or more adhesive receiving surfaces (surface preparation) of the complete vehicle roof assembly 102 are prepared, and adhesive is applied thereto. For example, it can be... Figure 6 The adhesive is applied in the second adhesive application pattern 604 shown. In operation 522, the vehicle roof fitting 102 is bonded to the vehicle. For example, as... Figure 1As shown, the vehicle roof fitting 102 can be adhered to the vehicle in a certain position and structure. Other positions, configurations, and various roof types are also possible.

[0054] In some examples, vehicle roof fittings are designed to mount one or more antennas directly within an external RF-transparent polymer roof panel. This integration helps maintain the vehicle's sleek design by eliminating the need for traditional external antennas, which can detract from the vehicle's aerodynamic shape and aesthetic appeal. The antennas are strategically embedded in or near the polymer material, chosen based on its RF transparency, ensuring there are no metallic obstructions that could impede signal transmission or reception.

[0055] In particular, integrated antenna configurations designed to meet stringent field-of-view (FOV) requirements can be important, or at least helpful, for robust communications. For LTE communications, in some examples, the antenna provides an FOV ranging from 0 to 30 degrees to the horizon, ensuring reliable connectivity to cellular networks. For GNSS communications, in some examples, an FOV of 75 degrees to the zenith is provided, allowing for precise satellite navigation without signal obstruction.

[0056] The antenna module and mounting housing, which house the integrated antenna, serve as a hub for various vehicle functions. It integrates multiple components, including those required for satellite communications, LTE communications, in-vehicle infotainment systems (such as microphones and switches), and external RF communications. This integration reduces endpoints and electrical connections within the vehicle, simplifies the assembly process, and improves overall system performance.

[0057] Furthermore, in some examples, the integrated antenna is designed to withstand adverse weather conditions, which can be a consideration for vehicle operation. Examples attempt to ensure that antenna performance is not affected by ice and snow buildup outside the vehicle. In some examples, this can be achieved without additional structural elements such as heater grids or wiping zones, which might otherwise be necessary to maintain antenna functionality under such conditions.

[0058] exist Figure 6 The image provides an enlarged view of the first vehicle roof mount 504, antenna module and mounting housing 222, enclosure panel 602 and complete vehicle roof mount 102, which shows an example second adhesive application pattern 604.

[0059] Figure 7 Table 702 shows example specifications for various components of the vehicle roof fitting 102.

[0060] refer to Figure 8The following describes example operations in method 800 for assembling a vehicle roof. Although the described process may be presented as a sequential procedure, many operations can be performed in parallel or simultaneously. Furthermore, the order of operations can be rearranged. A process terminates when the operations of one process are completed. A process can correspond to a method, a program, an algorithm, etc. The operations of a method can be performed in whole or in part, can be performed in combination with some or all of the operations in other methods, and can be performed by any number of different systems, such as the system described herein or any part thereof, such as a processor included in any system.

[0061] In operation 802, method 800 provides an external RF transparent polymer roof panel. In operation 804, method 800 attaches a plurality of mounting brackets to the external RF transparent polymer roof panel. In operation 806, method 800 aligns the external RF transparent polymer roof panel using a reference block. In operation 808, method 800 secures an internal substrate assembly, including an integrated isolator, to the external RF transparent polymer roof panel.

[0062] In some examples, method 800 may further include integrating one or more antennas within an external RF transparent polymer roof panel for RF communication. In some examples, method 800 may further include pre-filling the external RF transparent polymer roof panel with one or more electrical components and configuring the external RF transparent polymer roof panel as a single unit to be mounted into a vehicle roof sub-assembly.

[0063] In some examples, one or more electrical components include electrical components selected from the group including map lights, microphones, user-operable switches, satellite communication components, speakers, Bluetooth Low Energy components, and processors.

[0064] In some examples, method 800 also includes a polymer substrate enclosing the internal substrate assembly and bonding an insulating layer to the enclosing polymer substrate to enhance the thermal and acoustic insulation properties of the vehicle roof assembly.

[0065] In some examples, method 800 also includes selecting a material from the group of materials including polycarbonate (PC), acrylonitrile-butadiene-styrene (ABS), and acrylonitrile-styrene-acrylate (ASA) for the external RF transparent polymer roof panel. Method 800 may also include applying an adhesive between the external RF transparent polymer roof panel and the internal substrate assembly to allow deflection during a collision. Method 800 may also include molding one or more rib features into the RF transparent polymer roof, which lacks additional metal roof crossbeams.

[0066] In some examples, method 800 may also include testing whether the assembled RF transparent vehicle roof meets head-on collision safety standards. In some examples, the external RF transparent polymer roof panel is treated to be opaque to reduce solar radiation transmission into the vehicle interior. Method 800 may also include configuring the external RF transparent polymer roof panel and the internal substrate assembly to stroke together by deflection. Other technical features will be apparent to those skilled in the art from the following figures, description, and claims.

[0067] In some examples, the RF transparency of polymer roof panels facilitates the integration of vehicle roof fittings with other vehicle systems. This integration allows for seamless communication between the vehicle's internal electronic modules and external devices such as satellite and cellular networks, without the need for external antennas that could disrupt the vehicle's aerodynamic shape and aesthetic design.

[0068] In some examples, the manufacturing process for vehicle roof fittings incorporates techniques such as ultrasonic welding or thermoforming, which provide a strong and reliable bond between polymer components without compromising RF transparency. These processes are optimized for efficiency, reducing cycle time and cost while maintaining high-quality standards.

[0069] In some examples, the materials selected for vehicle roof fittings are chosen not only based on their functional properties but also on their environmental impact. The polymers used are recyclable, and their life cycle impact has been assessed to ensure that vehicle roof fittings are both sustainable and functional.

[0070] Example

[0071] Therefore, some embodiments may include one or more of the following examples.

[0072] Example 1. A vehicle roof fitting including an external RF transparent polymer roof panel; and an internal substrate fitting including an insulating layer integrated therein.

[0073] Example 2. The vehicle roof fitting according to Example 1, wherein the external RF transparent polymer roof panel is made of a material selected from the group of materials including polycarbonate (PC), acrylonitrile-butadiene-styrene (ABS) and acrylonitrile-styrene-acrylate (ASA).

[0074] Example 3. According to Example 1 or Example 2, the vehicle roof fitting also includes one or more antennas integrated within an external RF transparent polymer roof panel for communicating with external devices.

[0075] Example 4. A vehicle roof fitting according to any one of Examples 1 to 3, wherein an external RF transparent polymer roof panel is pre-filled with one or more electrical components and is configured to be installed as a single unit into a vehicle roof subfit.

[0076] Example 5. A vehicle roof fitting according to Example 4, wherein one or more electrical components include electrical components selected from the group comprising map lights, microphones, user-operable switches, satellite communication components, speakers, Bluetooth Low Energy components, and processors.

[0077] Example 6. A vehicle roof fitting according to any one of Examples 1 to 5, wherein the internal substrate fitting includes a wrapped polymer substrate and an insulating layer bonded to the wrapped polymer substrate to enhance the thermal and sound insulation properties of the vehicle roof fitting.

[0078] Example 7. A vehicle roof fitting according to any of Examples 1 to 6, wherein the external RF transparent polymer roof panel is opaque to reduce solar radiation transmission into the vehicle interior.

[0079] Example 8. A vehicle roof assembly according to any one of Examples 1 to 7, wherein an external RF transparent polymer roof panel and an internal substrate assembly are bonded together using an adhesive that allows the vehicle roof assembly to deflect during a collision.

[0080] Example 9. A vehicle roof fitting according to any one of Examples 1 to 8, wherein the external RF transparent polymer roof panel includes one or more molded rib features and eliminates the need for additional metal roof crossbeams.

[0081] Example 10. A vehicle roof fitting according to any one of Examples 1 to 9, wherein the external RF transparent polymer roof panel is dent-resistant and corrosion-resistant.

[0082] Example 11. A vehicle roof assembly according to any one of Examples 1 to 10, wherein the external RF transparent polymer roof panel and the internal substrate assembly are configured to stroke together by deflection.

[0083] Example 12. A method for mounting a vehicle roof, the method comprising: providing an external RF transparent polymer roof panel; attaching a plurality of mounting brackets to the external RF transparent polymer roof panel; aligning the external RF transparent polymer roof panel using a reference block; and securing an internal substrate assembly including an integrated isolator to the external RF transparent polymer roof panel.

[0084] Example 13. According to the method of Example 12, the method further includes integrating one or more antennas within an external RF transparent polymer roof panel for RF communication.

[0085] Example 14. According to the method of Example 12 or 13, the method further includes pre-filling the external RF transparent polymer roof panel with one or more electrical components and configuring the external RF transparent polymer roof panel as a single unit to be installed into the vehicle roof sub-assembly.

[0086] Example 15. According to the method of Example 14, one or more electrical components include electrical components selected from the group including map lights, microphones, user-operable switches, satellite communication components, speakers, Bluetooth Low Energy components, and processors.

[0087] Example 16. The method of any one of Examples 12 to 15, further comprising a polymer substrate enclosing an internal substrate assembly, and bonding an insulating layer to the enclosing polymer substrate to enhance the thermal and acoustic insulation properties of the vehicle roof assembly.

[0088] Example 17. The method according to any one of Examples 12 to 16, further comprising selecting a material for an external RF transparent polymer roof panel from the group of materials including polycarbonate (PC), acrylonitrile-butadiene-styrene (ABS) and acrylonitrile-styrene-acrylate (ASA).

[0089] Example 18. The method of any one of Examples 12 to 17, further comprising applying an adhesive between an external RF transparent polymer roof panel and an internal substrate assembly to allow deflection during a collision.

[0090] Example 19. The method of any one of Examples 12 to 18, further comprising molding one or more rib features into an RF transparent polymer roof that lacks additional metal roof crossbeams.

[0091] Example 20. The method according to any one of Examples 12 to 19 further includes testing whether the assembled RF transparent vehicle roof meets head impact safety standards.

[0092] Example 21. The method of any one of Examples 12 to 20, wherein the external RF transparent polymer roof panel is treated to be opaque to reduce solar radiation transmission into the vehicle interior.

[0093] Example 22. The method of any one of Examples 12 to 21, further comprising configuring the external RF transparent polymer roof panel and the internal substrate assembly to stroke together by deflection.

[0094] Example 23. A vehicle roof fitting kit comprising: an external RF transparent polymer roof panel; a plurality of mounting brackets; one or more reference blocks for alignment during assembly; and an internal substrate assembly including an integrated isolator.

[0095] Example 24. A vehicle roof fitting kit according to Example 23, wherein the external RF transparent polymer roof panel is made of a material selected from the group of materials including polycarbonate (PC), acrylonitrile-butadiene-styrene (ABS) and acrylonitrile-styrene-acrylate (ASA).

[0096] Example 25. According to Example 23 or 24, the vehicle roof accessory kit also includes one or more antennas for integration within an external RF transparent polymer roof panel for communication with external devices.

[0097] Example 26. A vehicle roof fitting kit according to any one of Examples 23 to 25, wherein an external RF transparent polymer roof panel is pre-filled with one or more electrical components and is configured to be installed as a single unit into a vehicle roof sub-fitting.

[0098] Example 27. A vehicle roof fitting kit according to Example 26, wherein one or more electrical components include electrical components selected from the group including map lights, microphones, user-operable switches, satellite communication components, speakers, Bluetooth Low Energy components, and processors.

[0099] Example 28. A vehicle roof fitting comprising: an external RF transparent polymer roof panel; and one or more antennas integrated within the external RF transparent polymer roof panel, wherein the one or more antennas are configured to communicate with external devices without metal obstruction.

[0100] Example 29. A vehicle roof fitting according to Example 28, wherein one or more antennas are configured to meet specific field of view (FOV) requirements, including a range of 0-30 degrees above the horizon for LTE communication and a range of 75 degrees above the zenith for GNSS communication.

[0101] Example 30. A vehicle roof fitting according to Example 28 or 29, wherein one or more antennas are part of an electronic module that integrates functions selected from a group including satellite communications, LTE communications, in-home infotainment, and external RF communications.

[0102] Example 31. A vehicle roof fitting according to any of Examples 28 to 30, wherein one or more antennas are designed to maintain performance in adverse weather conditions, such as the lack of a heater grid or wiping area, including the presence of ice or snow.

[0103] In some examples, methods for manufacturing vehicle roof assemblies include: selecting an RF-transparent polymer material for the exterior roof panel; bonding the exterior roof panel to an interior substrate assembly using an adhesive technique selected from the group consisting of ultrasonic welding, thermal fusion, and bonding; and integrating electronic modules within the exterior roof panel using a process that maintains the RF transparency of the assembly.

[0104] In some examples, the materials selected for the external RF transparent polymer roof panel and the internal substrate assembly are recyclable and chosen based on life cycle assessments to minimize environmental impact.

[0105] In some examples, an acoustic layer is integrated within the internal substrate assembly 106, wherein the acoustic layer is composed of a material selected from the group consisting of melamine foam, polyurethane foam and fiber insulating materials to enhance the sound insulation properties of the assembly.

[0106] In some examples, the isolation layer integrated within the internal substrate assembly includes an aerogel material that provides thermal insulation properties while minimizing layer thickness.

[0107] In some examples, the vehicle roof fitting kit includes: an external radio frequency transparent polymer roof panel pre-filled with electronic modules; an internal substrate assembly including an integrated isolation layer; and a set of modular components configured for rapid assembly onto a vehicle frame, wherein the modular components include at least one of a reference block, a mounting bracket, and a sealing element.

[0108] It should be noted that the above description and figures only illustrate the principles of this subject matter and the examples described herein, and should not be considered as limitations on this subject matter. Therefore, it should be understood that various devices can be designed, which, although not explicitly described or shown herein, embody the principles of this subject matter. Furthermore, all statements and specific examples of the principles, aspects, and implementations of this subject matter herein are intended to cover their equivalents.

[0109] It should be understood that not all objectives or advantages may be achieved according to any particular example described herein. Therefore, for example, those skilled in the art will recognize that some examples may operate in a manner that achieves or optimizes one or more advantages taught herein, without necessarily achieving other objectives or advantages taught or suggested herein.

[0110] All processes described herein can be embodied in software code modules executed by a computing system, including a computer or processor, and fully automated via such software code modules. The code modules can be stored on any type of non-transitory computer-readable medium or other computer storage device. Some or all of the methods can be embodied in dedicated computer hardware.

[0111] Based on this disclosure, many other variations besides those described herein will be apparent. For example, depending on the example, some actions, events, or functions of any of the algorithms described herein may be performed in a different sequence, may be added, combined, or omitted entirely (e.g., not all described actions or events are necessary for the practice of the algorithm). Furthermore, in some examples, actions or events may be performed concurrently, rather than sequentially, for example, through multithreading, interrupt handling, or multiple processors or processor cores, or on other parallel architectures. Additionally, different tasks or processes may be performed by different machines and / or computing systems that can work together.

[0112] The various illustrative logic blocks and modules described in conjunction with the examples disclosed herein can be implemented or executed by a machine such as a processing unit or processor, a digital signal processor (DSP), an application-specific integrated circuit (ASIC), a field-programmable gate array (FPGA) or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein. The processor may be a microprocessor, but alternatively, it may be a controller, a microcontroller, or a state machine, a combination thereof, etc. The processor may include circuitry that processes computer-executable instructions. In some examples, the processor includes an FPGA or other programmable device that performs logical operations without processing computer-executable instructions. The processor may also be implemented as a combination of computing devices, such as a combination of a DSP and a microprocessor, multiple microprocessors, a microprocessor incorporating a DSP core, or any other such configuration.

[0113] Although this document primarily describes digital technologies, processors can also primarily include analog components. The computing environment can include any type of computer system, including but not limited to microprocessor-based computer systems, mainframe computers, digital signal processors, portable computing devices, device controllers, or computing engines within devices. Elements of the methods, processes, routines, or algorithms described in conjunction with the embodiments disclosed herein can be directly embodied in hardware, software modules executed by the processor device, or a combination of both. Software modules can reside in RAM memory, flash memory, ROM memory, EPROM memory, EEPROM memory, registers, hard disks, removable disks, CD-ROMs, or any other form of non-transitory computer-readable storage medium. Exemplary storage media can be coupled to the processor device such that the processor device can read information from and write information to the storage medium. Alternatively, the storage medium can be integrated into the processor device. The processor device and storage medium can reside in an ASIC. The ASIC can reside in a user terminal. Alternatively, the processor device and storage medium can reside as discrete components in the user terminal.

[0114] The processes described herein or illustrated in the accompanying drawings may begin in response to an event, such as according to a predetermined or dynamically determined schedule, at the request of a user or system administrator, or in response to other events. When such a process is initiated, a set of executable program instructions stored on one or more non-transitory computer-readable media (e.g., hard disk drives, flash memory, removable media, etc.) may be loaded into the memory (e.g., RAM) of a server or other computing device. The executable instructions may then be executed by the hardware-based computer processor of the computing device. In some embodiments, these processes, or portions thereof, may be implemented serially or in parallel on multiple computing devices and / or multiple processors.

[0115] Although the flowcharts described herein may present operations as sequential processes, many operations can be executed in parallel or simultaneously. Furthermore, the order of operations can be rearranged. A process terminates when its operations are completed. A process can correspond to a method, procedure, algorithm, etc. The operations of a method can be executed entirely or partially, can be combined with some or all of the operations from other methods, and can be executed by any number of different systems, such as the system described herein or any part thereof, such as processors included in any system.

[0116] Among other things, conditional language, such as “can,” “could,” “might,” or “may,” unless otherwise specifically stated, is understood in context to generally convey that some examples include certain features, elements, and / or steps, while others do not. Therefore, such conditional language is generally not intended to imply that features, elements, and / or steps are examples in any way, or that examples must include logic for determining whether such features, elements, and / or steps are included in any particular example or whether they will be performed in any particular example, with or without user input or prompts.

[0117] Unless otherwise specifically stated, disjunctive language such as the phrase “at least one of X, Y, or Z” should be understood as generally used to indicate a context in which items, terms, etc., can be X, Y, or Z or any combination thereof (e.g., X, Y, and / or Z). Therefore, such disjunctive language is generally not intended to, nor should it imply, that some examples require the presence of at least one of X, at least one of Y, or at least one of Z.

[0118] Any process descriptions, elements, or blocks depicted in the flowcharts described herein and / or the accompanying drawings should be understood as potentially representing modules, segments, or code portions that include executable instructions for specific logical functions or elements during implementation. Alternative examples are included within the scope of the examples described herein, wherein elements or functions may be omitted, performed not in the order shown or discussed, including substantially simultaneously or in reverse order, depending on the functionality involved, as will be understood by those skilled in the art.

[0119] It should be emphasized that various changes and modifications can be made to the above examples, and their elements should be understood as other acceptable examples. All such modifications and changes are intended to be included within the scope of this disclosure.

[0120] Any process descriptions, elements, or blocks depicted in the flowcharts described herein and / or the accompanying drawings should be understood as potentially representing modules, segments, or code portions that include executable instructions for specific logical functions or elements during implementation. Alternative implementations are included within the scope of the examples described herein, wherein elements or functions may be omitted, performed out of the order shown or discussed, including substantially simultaneously or in reverse order, depending on the functionality involved, as understood by those skilled in the art.

[0121] Unless otherwise expressly stated, the article “a” or “an” should generally be interpreted as including one or more of the described items. Therefore, phrases such as “devices configured to…” are intended to include one or more of the described devices. Such one or more described devices may also be configured together to perform the stated descriptions. For example, “processors configured to perform descriptions A, B, and C” could include a first processor configured to perform description A working in conjunction with a second processor configured to perform descriptions B and C.

[0122] It should also be recognized that one or more of the components depicted in the drawings / figures may also be implemented in a more separate or integrated manner, or even removed or rendered inoperable in some cases, which may be useful depending on the specific application.

Claims

1. A vehicle roof fitting, comprising: External RF transparent polymer roof panel; as well as An internal substrate assembly, the internal substrate assembly including an isolation layer integrated therein.

2. The vehicle roof fitting according to claim 1, wherein the external RF transparent polymer roof panel is made of a material selected from the group consisting of polycarbonate PC, acrylonitrile-butadiene-styrene ABS and acrylonitrile-styrene-acrylate ASA.

3. The vehicle roof fitting according to claim 1 further includes one or more antennas integrated within the external RF transparent polymer roof panel, the one or more antennas being used to communicate with external devices.

4. The vehicle roof fitting of claim 1, wherein the external RF transparent polymer roof panel is pre-filled with one or more electrical components and is configured to be installed as a single unit into the vehicle roof sub-fitting.

5. The vehicle roof fitting of claim 4, wherein the one or more electrical components comprise electrical components selected from the group consisting of map lights, microphones, user-operable switches, satellite communication components, speakers, Bluetooth Low Energy components, and processors.

6. The vehicle roof fitting according to claim 1, wherein the internal substrate fitting includes a wrapped polymer substrate and an insulating layer bonded to the wrapped polymer substrate to enhance the heat insulation and sound insulation properties of the vehicle roof fitting.

7. The vehicle roof fitting according to claim 1, wherein the external RF transparent polymer roof panel is opaque to reduce solar radiation transmission into the vehicle interior.

8. The vehicle roof fitting of claim 1, wherein the external RF transparent polymer roof panel and the internal substrate fitting are bonded together using an adhesive that allows the vehicle roof fitting to deflect during a collision.

9. The vehicle roof fitting of claim 1, wherein the external RF transparent polymer roof panel includes one or more molded rib features and eliminates the need for additional metal roof crossbeams.

10. The vehicle roof fitting according to claim 1, wherein the external RF transparent polymer roof panel is dent-resistant and corrosion-resistant.

11. The vehicle roof assembly of claim 1, wherein the external RF transparent polymer roof panel and the internal substrate assembly are configured to stroke together by deflection.

12. A method for assembling a vehicle roof, the method comprising: Provide external RF transparent polymer roof panels; Multiple mounting brackets are attached to the external RF transparent polymer roof panel; Align the external RF transparent polymer roof panel using a reference block; as well as An internal substrate assembly, including an integrated isolator, is attached to the external RF transparent polymer roof panel.

13. The method of claim 12, further comprising integrating one or more antennas within the external RF transparent polymer roof panel for RF communication.

14. The method of claim 12, further comprising pre-filling the external RF transparent polymer roof panel with one or more electrical components, and configuring the external RF transparent polymer roof panel as a single unit to be installed into the vehicle roof sub-assembly.

15. The method of claim 14, wherein the one or more electrical components comprise electrical components selected from the group consisting of a map light, a microphone, a user-operable switch, a satellite communication component, a speaker, a Bluetooth Low Energy component, and a processor.

16. The method of claim 12, further comprising a polymer substrate enclosing the internal substrate assembly, and bonding an insulating layer to the enclosing polymer substrate to enhance the heat insulation and sound insulation properties of the vehicle roof assembly.

17. The method of claim 12, further comprising a material selected from the group consisting of polycarbonate PC, acrylonitrile-butadiene-styrene ABS and acrylonitrile-styrene-acrylate ASA for the external RF transparent polymer roof panel.

18. The method of claim 12, further comprising applying an adhesive between the external RF transparent polymer roof panel and the internal substrate assembly to allow deflection during a collision.

19. The method of claim 12, further comprising molding one or more rib features into an RF transparent polymer roof, the RF transparent polymer roof lacking additional metal roof crossbeams.

20. The method of claim 12 further includes testing whether the assembled RF transparent vehicle roof meets head impact safety standards.

21. The method of claim 12, wherein the external RF transparent polymer roof panel is processed to be opaque to reduce solar radiation transmission into the vehicle interior.

22. The method of claim 12, further comprising configuring the external RF transparent polymer roof panel and the internal substrate assembly to perform a joint stroke via deflection.

23. A vehicle roof fitting kit, comprising: External RF transparent polymer roof panel; Multiple mounting brackets; One or more reference blocks, said one or more reference blocks being used for alignment during assembly; as well as An internal substrate assembly, the internal substrate assembly including an integrated isolator.

24. The vehicle roof fitting kit of claim 23, wherein the external RF transparent polymer roof panel is made of a material selected from the group consisting of polycarbonate PC, acrylonitrile-butadiene-styrene ABS and acrylonitrile-styrene-acrylate ASA.

25. The vehicle roof fitting kit of claim 23 further includes one or more antennas integrated within the external RF transparent polymer roof panel for communicating with external devices.

26. The vehicle roof fitting kit of claim 23, wherein the external RF transparent polymer roof panel is pre-filled with one or more electrical components and is configured to be installed as a single unit into the vehicle roof sub-fitting.

27. The vehicle roof fitting kit of claim 26, wherein the one or more electrical components comprise electrical components selected from the group consisting of map lights, microphones, user-operable switches, satellite communication components, speakers, Bluetooth Low Energy components, and processors.

28. A vehicle roof fitting, comprising: External RF transparent polymer roof panel; and one or more antennas integrated within the external RF transparent polymer roof panel, wherein the one or more antennas are configured to communicate with external devices without metal obstruction.

29. The vehicle roof fitting of claim 28, wherein the one or more antennas are configured to meet specific field of view (FOV) requirements, including a range of 0 to 30 degrees from the horizon for LTE communication and a range of 75 degrees from the zenith for GNSS communication.

30. The vehicle roof fitting of claim 28, wherein the one or more antennas are part of an electronic module that integrates functions selected from the group consisting of satellite communication, LTE communication, in-home infotainment, and external RF communication.

31. The vehicle roof fitting of claim 28, wherein the one or more antennas are designed to maintain performance in adverse weather conditions, including the absence of heater grids or wiping areas, said weather conditions including the presence of ice or snow.

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