Transparent composite material for vehicle window brow

Abstract

This application relates to a transparent composite material for a vehicle window brow. The present disclosure provides a window brow for a vehicle upper body structure. The window brow includes an elongated body extending between a first side and a second side. The elongated body comprises a polymer and a plurality of fibers. The elongated body includes a front end and a rear end. The front end is configured to be joined to a windshield. The rear end is configured to be joined to a roof. At least a portion of the elongated body has a transparency of greater than or equal to about 4%.

Description

Technical Field

[0001] The present disclosure relates to a transparent component for an upper body structure of a vehicle. Background Art

[0002] This section provides background information related to the present disclosure, which is not necessarily prior art.

[0003] The vehicle upper body assembly provides structural support and mounting locations for other vehicle components. Advantageously, the strength and structural performance of the vehicle upper body assembly are improved. However, it is also advantageous to lightweight components in an automobile or other vehicle to improve efficiency. In addition, it is advantageous for components of the structural assembly to be at least partially transparent to improve occupant visibility and / or aesthetics. Thus, it is advantageous for vehicle components in a structural assembly that exhibit sufficient strength during normal use while minimizing component weight and improving occupant visibility. Summary of the Invention

[0004] This section provides a general overview of the present disclosure, not an exhaustive disclosure of its full scope or all of its features.

[0005] The present disclosure relates to a transparent composite vehicle header and a vehicle upper body assembly including the transparent header.

[0006] In various aspects, the present disclosure provides a header for a vehicle upper body structure. The header includes an elongated body extending between a first side and a second side. The elongated body includes a polymer and a plurality of fibers. The elongated body includes a front end and a rear end. The front end is configured to be coupled to a windshield. The rear end is configured to be coupled to a roof. At least a portion of the elongated body has a transparency greater than or equal to about 4%.

[0007] In one aspect, the header has a transparency greater than or equal to about 50% to less than or equal to about 99%.

[0008] In one aspect, the volume percentage of the plurality of fibers is greater than or equal to about 5 volume % to less than or equal to about 35 volume %.

[0009] In one aspect, the local tensile strength of the elongated body is greater than or equal to 40 MPa to less than or equal to 1000 MPa.

[0010] In one aspect, the header includes a first component and a second component. The second component is coupled to the first component.

[0011] In one aspect, at least a portion of the elongate body is fiber-free.

[0012] In one aspect, the plurality of fibers are dispersed substantially uniformly throughout the elongate body.

[0013] In one aspect, the elongate body includes a first region and a second region. The first region has a first transparency and a first tensile strength. The second region has a second transparency and a second tensile strength. The second transparency is greater than the first transparency. The second tensile strength is less than the first tensile strength.

[0014] In one aspect, the first region includes a first outer region and a second outer region. The first outer region includes the first side. The second outer region includes the second side. The second region is disposed at least partially between the first outer region and the second outer region.

[0015] In one aspect, the second region comprises a polymer that is substantially fiber-free. The first region comprises the polymer and the plurality of fibers.

[0016] In one aspect, the first region includes the rear end. The second region includes the front end.

[0017] In one aspect, the elongate body defines a transparency gradient.

[0018] In one aspect, the transparency gradient includes a plurality of transparency gradients.

[0019] In one aspect, the plurality of transparency gradients includes a first gradient and a second gradient having a rate of change that is substantially equal to the first gradient.

[0020] In one aspect, the polymer is selected from: epoxy, polyurethane (PUR), polycarbonate (PC), polymethyl methacrylate (PMMA), polyethylene terephthalate (PET), polyacrylate (acrylic), polyamide (PA), copolymers thereof, and combinations thereof.

[0021] In one aspect, the plurality of fibers are selected from: glass fibers, carbon fibers, basalt fibers, aramid fibers, polyethylene fibers, polypropylene fibers, natural fibers, or any combination thereof.

[0022] In one aspect, the plurality of fibers have a shape selected from: cylindrical, flat, or both cylindrical and flat. The plurality of fibers have an orientation selected from: continuous in a first planar direction, discontinuous in a first planar direction, discontinuous in a plurality of directions, or any combination thereof.

[0023] In one aspect, the plurality of fibers include a plurality of continuous fibers and a plurality of discontinuous fibers.

[0024] In one aspect, the elongate body further comprises an additive selected from: ultraviolet light absorbers, quenchers, hindered amine light stabilizers (HALS), or combinations thereof.

[0025] In various aspects, the present disclosure provides an upper body structure. The upper body structure includes a first side structure, a second side structure, a roof, and a window molding. The window molding includes an elongate body extending between a first side and a second side. The elongate body comprises a polymer and a plurality of fibers. The window molding further includes a front end and a rear end. The front end is configured to engage a windshield. The rear end is configured to engage the roof. The first side is configured to engage the first side structure. The second side is configured to engage the second side structure. At least a portion of the elongate body has a transparency greater than or equal to about 4%.

[0026] Other applicable fields will become apparent from the description provided herein. The description and specific examples in this summary are intended for illustration only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.

[0028] Figure 1 is a perspective view of a vehicle upper body structure including a window molding and a roof according to various aspects of the present disclosure;

[0029] Figure 2A is according to various aspects of the present disclosure Figure 1 of the window molding;

[0030] Figure 2B is at Figure 1 taken along line 2B-2B of Figure 1 partial cross-sectional view of the upper body structure;

[0031] Figure 3A is a top view of another window molding according to various aspects of the present disclosure;

[0032] Figure 3B is Figure 3A schematic diagram of the window molding;

[0033] Figure 4A is a top view of another window header according to various aspects of the present disclosure;

[0034] Figure 4B is Figure 4A a schematic diagram of the window header of

[0035] Figure 5A is a top view of another window header according to various aspects of the present disclosure;

[0036] Figure 5B is Figure 5A a schematic diagram of the window header of

[0037] Figure 6 is a perspective view of another window header according to various aspects of the present disclosure;

[0038] Figure 7 is according to various aspects of the present disclosure Figure 1 a top view of the vehicle roof of

[0039] Figure 8 is a top view of another vehicle roof according to various aspects of the present disclosure; and

[0040] Figure 9 is a top view of another vehicle roof according to various aspects of the present disclosure.

[0041] Throughout several views of the drawings, corresponding reference numerals indicate corresponding parts. Detailed Description

[0042] Exemplary embodiments are provided so that the present disclosure will be thorough and will fully convey its scope to those skilled in the art. Numerous specific details are set forth such as examples of specific compositions, components, devices, and methods to provide a full understanding of the embodiments of the present disclosure. It will be apparent to those skilled in the art that the exemplary embodiments may be embodied in many different forms without the use of specific details and that none of them should be construed as limiting the scope of the present disclosure. In some exemplary embodiments, well-known methods, well-known device structures, and well-known technologies are not described in detail.

[0043] The terms used herein are for the purpose of describing particular exemplary embodiments only and are not intended to be limiting. Unless the context clearly dictates otherwise, as used herein, the singular forms "a," "an," and "the" may be intended to include the plural forms as well. The terms "comprising," "including," "containing," and "having" are inclusive and thus specify the presence of the stated features, elements, compositions, steps, integers, operations, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. Although the open-ended term "comprising" is to be understood as a non-limiting term used to describe and claim the various embodiments herein, in some instances, the term may instead be understood to be more limiting and restrictive, such as "consisting of" or "consisting essentially of." Thus, for any given embodiment reciting a composition, material, component, element, feature, integer, operation, and / or process step, the present disclosure also specifically includes embodiments consisting of or consisting essentially of such recited composition, material, component, element, feature, integer, operation, and / or process step. In the case of "consisting of," alternative embodiments exclude any additional compositions, materials, components, elements, features, integers, operations, and / or process steps, while in the case of "consisting essentially of," any additional compositions, materials, components, elements, features, integers, operations, and / or process steps that materially affect the basic and novel characteristics are excluded from such embodiments, but any compositions, materials, components, elements, features, integers, operations, and / or process steps that do not materially affect the basic and novel characteristics may be included in such embodiments.

[0044] Any method steps, processes, and operations described herein should not be construed as necessarily requiring that they be performed in the particular order discussed or shown, unless specifically determined to be an order of performance. It is also to be understood that, unless otherwise stated, additional or alternative steps may be used.

[0045] When a component, element, or layer is referred to as being "on," "engaged to," "connected to," or "coupled to" another element or layer, it can be directly on, engaged to, connected to, or coupled to the other component, element, or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being "directly on," "directly engaged to," "directly connected to," or "directly coupled to" another element or layer, intervening elements or layers may not be present. Other words used to describe the relationship between elements should be interpreted in a like manner (e.g., "between" vs. "directly between," "adjacent" vs. "directly adjacent," etc.). As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0046] Although the terms first, second, third, etc. may be used herein to describe various steps, elements, components, regions, layers, and / or sections, these steps, elements, components, regions, layers, and / or sections should not be limited by these terms unless otherwise specified. These terms may be used only to distinguish one step, element, component, region, layer, or section from another step, element, component, region, layer, or section. Unless clearly stated in the context, terms such as "first", "second", and other numerical terms do not imply an order or sequence when used herein. Thus, the first step, element, component, region, layer, or section discussed below may be referred to as the second step, element, component, region, layer, or section without departing from the teachings of the exemplary embodiments.

[0047] For ease of description, relative terms of space or time, such as "before", "after", "inside", "outside", "below", "beneath", "lower", "above", "upper", etc., may be used herein to describe the relationship of one element or feature shown in the figures to other elements or features. Relative terms of space or time are intended to include different orientations of the device or system in use or operation, in addition to the orientation shown in the figures.

[0048] Throughout this disclosure, numerical values represent approximate measurements or range limits to include slight deviations from a given value and embodiments that generally have the listed value and embodiments that exactly have the listed value. Except in the examples provided at the end of the detailed description section, all numerical values of parameters (such as amounts or conditions) in this specification (including the appended claims) should be understood to be modified in all cases by the term "about", whether or not the term "about" actually appears before the numerical value. "About" means that the stated numerical value allows for a certain degree of imprecision (somewhat close to the exact value; generally or reasonably close to the value; almost). If the imprecision provided by "about" is not understood in this ordinary sense in the art, then "about" as used herein means at least the variations that may be caused by ordinary methods of measuring and using such parameters. For example, "about" may include variations of less than or equal to 5%, optionally less than or equal to 4%, optionally less than or equal to 3%, optionally less than or equal to 2%, optionally less than or equal to 1%, optionally less than or equal to 0.5%, and in some aspects optionally less than or equal to 0.1%.

[0049] In addition, the disclosure of a range includes the disclosure of all values within the entire range and further sub - ranges within the range, including the endpoints and sub - ranges given for these ranges.

[0050] Exemplary embodiments will now be described more fully with reference to the accompanying drawings.

[0051] A structural assembly can be used in a vehicle to provide structural support and / or mounting locations for other vehicle components. The structural assembly for an upper body structure can include a plurality of upper body components, such as a front window brow, a rear window brow, a roof, a driver's side roof rail, a passenger's side roof rail, and multiple pairs of structural struts. The roof can extend substantially rearward in the vehicle and connect the driver's side roof rail to the passenger's side roof rail. The window brow assembly can connect the driver's side roof rail to the passenger's side roof rail. The window brow assembly can support both the roof and the windshield and connect the roof to the windshield. Advantageously, the upper body structure has high stiffness and strength in local regions near the roof rails and the structural struts, particularly near the junctions of the window brow with the roof rails and the roof with the roof rails.

[0052] Some structural components, including upper body components, can be made of metal (such as steel). Some structural components can be made of opaque fiber-reinforced composite materials.

[0053] Some structural components, including upper body components, can be made of glass (such as a sunroof). Some structural components can be made of laminated composite materials. Some structural assemblies including glass and / or laminated composite components can be integrally formed with additional reinforcing components to achieve the desired strength and mechanical properties.

[0054] The upper body components can be opaque and thus reduce or inhibit the visibility of the occupants in the corresponding vehicle area. Some upper body structures can be very complex to assemble due to a large number of reinforcing components. In addition, structural assemblies including metal and / or glass components can be heavy, resulting in reduced fuel efficiency and / or reduced battery range of the vehicle.

[0055] In various aspects, the present disclosure provides transparent components (also referred to as "upper body components") for a vehicle upper body structure. The upper body components can be configured to provide structural support, occupant visibility, and shield the occupants from rain, snow, ultraviolet (UV) light, and other weather. As used herein, transparent means that at least a portion of the component has a transparency greater than 0%. The upper body components can be made of or include fiber-reinforced composite materials. The fiber-reinforced composite materials can include a polymer and a plurality of fibers. In certain aspects, the transparent component can include a first region having a relatively high strength and a relatively low transparency and a second region having a relatively low strength and a relatively high transparency. In certain aspects, the transparent component can include a window brow (such as a front window brow and / or a rear window brow), a roof, or a window brow and a roof. In certain aspects, the present disclosure provides an upper body structure including a window brow and a roof, wherein at least one of the window brow and the roof (optionally both the window brow and the roof) is transparent.

[0056] A fiber-reinforced composite vehicle body component according to various aspects of the present disclosure can be lighter than metal and / or glass vehicle body components. Such lighter vehicle body components can improve vehicle fuel efficiency and / or battery range. In some aspects, the vehicle body component can include a plurality of regions having customized strength and transparency. For example, regions expected to withstand higher loads can have high strength (e.g., near the connection of the vehicle body component and the roof rail and / or the pillar connection). Regions expected to withstand lower loads (e.g., near the vehicle centerline) can include a transparent polymer and have a reduced fiber volume fraction, different types of fibers (e.g., material, length, and / or layout), or be substantially fiber-free, and can thus exhibit higher transparency than regions with higher strength.

[0057] In various aspects, the stiffness and strength of the at least partially transparent upper body assembly can achieve the required mechanical properties of the upper body structure. In some aspects, the at least partially transparent assembly can be free of additional reinforcement components. In some aspects, the local tensile strength (tensile strength in at least one region of the upper body assembly) of the upper body assembly can be greater than or equal to about 40 MPa, optionally greater than or equal to about 100 MPa, optionally greater than or equal to about 200 MPa, optionally greater than or equal to about 300 MPa, optionally greater than or equal to about 400 MPa, optionally greater than or equal to about 600 MPa, optionally greater than or equal to about 800 MPa, optionally greater than or equal to about 1000 MPa, optionally greater than or equal to about 1200 MPa, optionally greater than or equal to about 1400 MPa, optionally greater than or equal to about 1600 MPa, optionally greater than or equal to about 1800 MPa, optionally greater than or equal to about 2000 MPa, optionally greater than or equal to about 2200 MPa, or optionally greater than or equal to about 2400 MPa. In some aspects, the tensile modulus of the upper body assembly can be greater than or equal to about 4 GPa, optionally greater than or equal to about 6 GPa, optionally greater than or equal to about 8 GPa, optionally greater than or equal to about 10 GPa, optionally greater than or equal to about 50 GPa, optionally greater than or equal to about 100 GPa, optionally greater than or equal to 200 GPa, optionally greater than or equal to 300 GPa, optionally greater than or equal to 400 GPa, or optionally greater than or equal to 500 GPa. The torsional stiffness of the upper body assembly can be greater than or equal to about 24 kNm / deg, optionally greater than or equal to about 26 kNm / deg, optionally greater than or equal to about 28 kNm / deg, optionally greater than or equal to about 30 kNm / deg, optionally greater than or equal to about 32 kNm / deg, optionally greater than or equal to about 34 kNm / deg, optionally greater than or equal to about 36 kNm / deg, optionally greater than or equal to about 38 kNm / deg, or optionally greater than or equal to 40 kNm / deg.

[0058] The upper body assembly can be configured to achieve a desired maximum deflection. The deflection can be measured by the amount of displacement of the assembly under an applied linear unit load. In one example, under an applied linear unit load of 1 kN, the deflection of the upper body assembly can be less than or equal to about 0.6 mm, optionally less than or equal to about 0.5 mm, optionally less than or equal to about 0.4 mm, optionally less than or equal to 0.3 mm, optionally less than or equal to about 0.2 mm, optionally less than or equal to about 0.1 mm, or optionally less than or equal to about 0.05 mm.

[0059] In various aspects, the transparent upper vehicle body component improves occupant visibility compared to a substantially opaque upper vehicle body component. At least a portion (or optionally substantially the entire transparent upper vehicle body component) of the transparent upper vehicle body component may have a transparency or average light transmittance that is greater than or equal to about 4% to less than or equal to about 99%, or optionally greater than or equal to about 50% to less than or equal to about 99%. In some aspects, the portion may have a transparency that is greater than or equal to about 4%, optionally greater than or equal to about 10%, optionally greater than or equal to about 15%, optionally greater than or equal to about 20%, optionally greater than or equal to about 25%, optionally greater than or equal to about 30%, optionally greater than or equal to about 35%, optionally greater than or equal to about 40%, optionally greater than or equal to about 45%, optionally greater than or equal to about 50%, optionally greater than or equal to about 55%, optionally greater than or equal to about 60%, optionally greater than or equal to about 65%, optionally greater than or equal to about 70%, optionally greater than or equal to about 75%, optionally greater than or equal to about 80%, optionally greater than or equal to about 85%, optionally greater than or equal to about 90%, or optionally greater than or equal to about 95%. In some aspects, the transparency is less than or equal to about 100%, optionally less than or equal to about 90%, optionally less than or equal to about 80%, optionally less than or equal to about 70%, optionally less than or equal to about 60%, optionally less than or equal to about 50%, optionally less than or equal to about 40%, optionally less than or equal to about 30%, optionally less than or equal to about 20%, or optionally less than or equal to about 10%.

[0060] In one example, the transparent upper vehicle body component includes two regions. The first region has a transparency that is greater than or equal to 0% to less than or equal to about 20%. The second region has a transparency that is greater than or equal to about 20% to less than or equal to about 99%.

[0061] In another example, the transparent upper vehicle body component includes a first region having a first transparency that is greater than or equal to about 0% to less than or equal to about 4%. The upper vehicle body component further includes a second region having a second transparency that is greater than or equal to about 5% to less than or equal to about 99%.

[0062] The upper body assembly according to various aspects of the present disclosure may include a polymer and a plurality of fibers. The polymer may be a thermosetting polymer or a thermoplastic polymer that is substantially transparent when free of fibers. In some aspects, the polymer may be a thermosetting polymer selected from the group consisting of: benzoxazine, bismaleimide (BMI), cyanate ester, epoxy resin, phenolic resin (PF), polyacrylate (acrylic), polyimide (PI), unsaturated polyester, polyurethane (PUR), vinyl ester, silicone, copolymers thereof, and combinations thereof. In some aspects, the polymer may be a thermoplastic polymer selected from the group consisting of: polyethyleneimine (PEI), polyamide-imide (PAI), polyamide (PA) (such as nylon 6, nylon 66, nylon 12), polyetheretherketone (PEEK), polyetherketone (PEK), polyphenylene sulfide (PPS), thermoplastic polyurethane (TPU), polypropylene (PP), polycarbonate / acrylonitrile butadiene styrene (PC / ABS), high density polyethylene (HDPE), polyethylene terephthalate (PET), poly(methyl methacrylate) (PMMA), polycarbonate (PC), polyaryletherketone (PAEK), polyetherketoneketone (PEKK), copolymers thereof, and combinations thereof. In some aspects, the upper body assembly may include more than one polymer. In some aspects, the upper body assembly may further include a polymer that is substantially opaque, such as in regions of lower transparency or opacity.

[0063] In some aspects, the plurality of fibers (also referred to as "fibers") may have lengths and / or orientations to meet the strength requirements of a vehicle upper body assembly. In some aspects, the fibers may be continuous and oriented in a substantially consistent direction, discontinuous and oriented in a substantially consistent direction, discontinuous and oriented in a random direction, or any combination thereof. The length of the discontinuous fibers may be less than the length of the continuous fibers. The length of the discontinuous fibers may be greater than or equal to a critical length such that when the upper body assembly is exposed to tensile stress or compressive stress, substantially complete load transfer from the fibers to the polymer matrix may occur. The critical length depends on the material. In one example, for glass fibers in an epoxy resin matrix, the critical length is about 97.5 µm. The substantially consistent direction may be in a first planar direction such that the upper body assembly has increased strength in the first planar direction. The upper body assembly may optionally include more than one fiber orientation to achieve the desired mechanical strength and / or stiffness.

[0064] In some aspects, the fibers may have a substantially cylindrical shape, a substantially flat shape, or both a substantially cylindrical shape and a substantially flat shape. The fiber shape may be defined by length, width, and thickness. The fiber length may be greater than or equal to the critical length. In some aspects, the length is about 10 times the effective diameter of the fiber.

[0065] The basic flat shape can be defined by a first dimension, a second dimension, and a third dimension (such as thickness). In some aspects, the third dimension is less than the first dimension and / or the second dimension. In some aspects, the third dimension can be less than or equal to about 25% of the first dimension and / or the second dimension, optionally less than or equal to about 20% of the first dimension and / or the second dimension, optionally less than or equal to about 15% of the first dimension and / or the second dimension, or optionally less than or equal to about 10% of the first dimension and / or the second dimension. In one example, the basic flat fiber has a first dimension of about 28 mm, a second dimension of about 7 mm, and a third dimension of about 3 mm.

[0066] In some aspects, the upper body assembly can include continuous fibers having a substantially cylindrical shape and oriented substantially in a first planar direction. In some aspects, the upper body assembly can include discontinuous fibers having a substantially cylindrical shape and oriented substantially in a first planar direction. In some aspects, the upper body assembly can include discontinuous fibers optionally having a substantially flat shape and oriented substantially in a first planar direction.

[0067] As an example, suitable fiber materials can include carbon fibers (such as carbon black, carbon nanotubes, talc, fibers derived from polyacrylonitrile and / or pitch precursors), glass fibers (such as fiberglass, quartz), basalt fibers, aramid fibers (such as KEVLAR®, poly(p-phenylene-2,6-benzobisoxazole) (PBO)), polyethylene fibers (such as high-strength ultra-high molecular weight (UHMW) polyethylene), polypropylene fibers (such as high-strength polypropylene), natural fibers (such as cotton, linen, cellulose, spider silk), and combinations thereof.

[0068] In some aspects, the upper body assembly can include the fibers in an amount greater than or equal to 5% by volume, optionally greater than or equal to about 10% by volume, optionally greater than or equal to about 20% by volume, optionally greater than or equal to about 30% by volume, optionally greater than or equal to about 35% by volume, or optionally greater than or equal to about 40% by volume. In some aspects, the upper body assembly can include fibers in an amount less than or equal to about 60% by volume, optionally less than or equal to about 50% by volume, optionally less than or equal to about 40% by volume, or optionally less than or equal to about 30% by volume.

[0069] In various aspects, the strength and transparency of the upper body assembly can be customized to achieve the desired performance. In some aspects, the volume percentage (or volume fraction) of the fibers can be substantially uniform throughout the upper body assembly. In some other aspects, the upper body assembly can include a plurality of regions or zones. The volume percentage of the fibers in each region or zone can be the same or different such that the volume percentage of the fibers can vary throughout the upper body assembly.

[0070] In some aspects, a region including a higher volume percentage of fibers can include the fibers in an amount greater than or equal to 40 volume %, optionally greater than or equal to 50 volume %, or optionally greater than or equal to 60 volume %. In some aspects, a region including a lower volume percentage of fibers can include the fibers in an amount less than or equal to about 40 volume %, optionally less than or equal to about 30 volume %, optionally less than or equal to about 20 volume %, less than or equal to about 10 volume %, or optionally less than or equal to 5 volume %. The volume percentage can depend on the strength and / or stiffness characteristics of the fiber material and can be selected to meet the desired strength and / or stiffness characteristics of the upper body assembly.

[0071] In some aspects, the upper body assembly can include a high-strength region (or optionally a plurality of high-strength regions) where high stiffness and / or strength are required, for example, due to expected loads. The high-strength region can include a higher volume percentage of fibers compared to other regions.

[0072] In some aspects, the upper body assembly can include a high-transparency region (or optionally a plurality of high-transparency regions) where high transparency is required. The high-transparency region can include a lower volume percentage of fibers compared to other regions.

[0073] A region having a high volume percentage of fibers, such as from greater than or equal to about 10 volume % to less than or equal to 40 volume % of fibers (or optionally greater than or equal to about 40 volume % of fibers), can have a higher tensile strength compared to a region having a low volume percentage of fibers (such as less than or equal to about 10 volume % of fibers, or optionally no fibers). However, a region having a high volume percentage of fibers can have a lower transparency compared to a region having a low volume percentage of fibers. In some aspects, a region having a high volume percentage of fibers can be at least partially transparent. In some aspects, a region having a significantly high volume percentage of fibers can be substantially opaque.

[0074] In various aspects, the strength and transparency of the upper body assembly can be customized through polymer and / or fiber selection. In some aspects, each region may include the same polymer and / or fiber. In some other aspects, each region may include different polymers and / or fibers. In some aspects, a region may include a polymer substantially free of fibers (e.g., when high transparency is desired). The polymer substantially free of fibers may be the same as or different from the polymer in a region that includes both a polymer and fibers. Any polymer combination including any fiber combination can be used and configured to provide the desired strength and transparency characteristics of the upper body assembly.

[0075] In various aspects, the strength of the upper body assembly can be customized through fiber orientation. In some aspects, continuous fibers can be oriented in a planar direction (e.g., by a unidirectional pre-impregnation molding process) (also referred to as "continuous unidirectional fibers"). The continuous unidirectional fibers can have high strength in the planar direction. However, the continuous unidirectional fibers can have relatively low strength in a non-planar direction. In one example, the continuous unidirectional fibers can be included in an upper body assembly where the desired strength and / or stiffness is in a substantially planar direction.

[0076] In some aspects, the fibers can be discontinuous and oriented in multiple directions (e.g., randomly oriented in-plane) (also referred to as "discontinuous in-plane random fibers"). In one example, the discontinuous in-plane random fibers can be included in an upper body assembly where the desired strength and / or stiffness is in multiple directions.

[0077] In some aspects, the fibers can be discontinuous and oriented in a planar direction (also referred to as "discontinuous in-plane oriented fibers"). Fibers oriented in a planar direction can have increased strength in the planar direction. However, in various aspects, the strength characteristics of an upper body assembly including discontinuous in-plane oriented fibers can be customized through fiber shape.

[0078] In some aspects, compared to substantially cylindrical fibers, substantially flat fibers can have an increased surface area. The increased surface area can increase the strength of the assembly in a second direction (e.g., the strength increased in a direction substantially perpendicular to the fiber orientation direction). Thus, compared to an upper body assembly including substantially cylindrical fibers, an upper body assembly including substantially flat fibers can have increased strength in more than one direction.

[0079] In various aspects, the transparency of the upper body component can also be customized using the fiber shape. Compared to fibers that are substantially cylindrical, the substantially flat fibers can have a surface with a lower curvature. The lower curvature surface can increase transparency (e.g., the lower curvature of the substantially flat fibers can reduce the amount of light distortion). Thus, an upper body component including substantially flat fibers can have increased transparency compared to an upper body component including substantially cylindrical fibers. The fiber orientation and shape can be varied and / or combined as needed to provide the desired strength and transparency characteristics at different regions of the upper body component.

[0080] In various aspects, the strength and transparency of the upper body component can be customized by the component thickness. In some aspects, in regions where higher strength and lower transparency are desired, the upper body component can have an increased thickness, such as a thickness greater than or equal to about 2 mm, optionally greater than or equal to about 4 mm, optionally greater than or equal to about 6 mm, or optionally greater than or equal to about 8 mm. The increased thickness can be less than or equal to about 10 mm, optionally less than or equal to 8 mm, optionally less than or equal to about 6 mm, or optionally less than or equal to about 4 mm. In some aspects, in regions where lower strength and higher transparency are desired, the upper body component can have a reduced thickness, such as a thickness greater than or equal to about 1 mm, optionally greater than or equal to about 2 mm, optionally greater than or equal to about 3 mm, optionally greater than or equal to about 4 mm, optionally greater than or equal to about 5 mm, optionally greater than or equal to about 6 mm, or optionally greater than or equal to about 7 mm. The reduced thickness can be less than or equal to about 8 mm, optionally less than or equal to about 7 mm, optionally less than or equal to about 6 mm, optionally less than or equal to about 5 mm, optionally less than or equal to about 4 mm, optionally less than or equal to about 3 mm, or optionally less than or equal to about 2 mm. The thickness can be varied as needed to provide structural support, strength, and / or transparency at the desired regions of the upper body component.

[0081] In various aspects, the upper body component can include one or more additives to achieve the desired properties. In some aspects, certain properties of the polymer of the upper body component may change over time when exposed to UV light from the sun. In some aspects, the polymer can include additives (e.g., chemical groups) configured to absorb UV light. The polymer can include chromophores. In some aspects, the polymer can include halogenated flame retardants, fillers, pigments, and / or combinations thereof. In some aspects, the polymer can include multiple additives. The additives can include UV absorbers, quenchers, hindered amine light stabilizers (HALS), or any combination thereof. In some aspects, the additives can be added in amounts that do not significantly impede the desired transparency.

[0082] In some aspects, the UV absorber can be configured to dissipate heat through the polymer (e.g., convert UV radiation into infrared radiation). In some aspects, the UV absorber includes carbon black, rutile titanium oxide, hydroxybenzophenone, hydroxyphenylbenzotriazole, oxanilides (e.g., in the upper body assembly including PA), benzophenones (e.g., in the upper body assembly including PVC), benzotriazoles (e.g., in the upper body assembly including PC), hydroxyphenyltriazines (e.g., in the upper body assembly including PC), or combinations thereof.

[0083] In some aspects, during UV light exposure, the chromophore can obtain energy from the UV light and change its energy state from a lower-energy ground state to a higher-energy excited state. In some aspects, the quencher can be configured to return the chromophore from the higher-energy excited state to the lower-energy ground state. In some aspects, the quencher includes the element nickel (Ni).

[0084] In some aspects, the HALS can be configured to capture free radicals formed during UV light exposure. The HALS can include a 2,2,6,6-tetramethylpiperidine ring structure. In some aspects, the additive can include a combination of a UV absorber, a quencher, and / or HALS to achieve the desired strength, transparency, and coloration characteristics.

[0085] In some aspects, the upper body assembly can be formed by compression molding. In some other aspects, the upper body assembly can be formed by injection molding. In some aspects, the molding process can utilize a preformed pre-impregnated polymer, a fiber-free preformed polymer (e.g., dry fiber preform), or both a preformed pre-impregnated polymer and a fiber-free preformed polymer.

[0086] Refer to Figure 1, a vehicle upper body structure 100 is provided in accordance with various aspects of the present disclosure. The upper body structure 100 may at least partially define an upper perimeter of a vehicle passenger compartment 102. The upper body structure 100 includes a pair of substantially laterally spaced apart A-pillars 104 and a pair of roof rails 106. The roof rails may include a driver-side roof rail 108 and a passenger-side roof rail 110. The A-pillars 104 may be substantially parallel and may project substantially forward in the vehicle. The roof rails 106 may be fixed to or integrally formed with the corresponding A-pillars 104. The roof rails 106 may extend substantially rearward along a longitudinal length 112 of the vehicle. Alternative vehicle architectures may include additional structural pillars (not shown). The pillars may optionally include a pair of B-pillars, a pair of C-pillars, and optionally a pair of D-pillars. The pillars may extend substantially vertically from the roof rails 106 and may be configured to connect the upper body structure 100 to a lower body structure (not shown), further defining the passenger compartment 102.

[0087] A roof 120 may be at least partially disposed between the roof rails 106. The roof 120 may extend substantially laterally across a transverse width 122 of the vehicle and substantially longitudinally across the longitudinal length 112 of the vehicle. The roof 120 may be configured to provide structural support, occupant visibility, and shelter the occupants from rain, snow, UV light, and other weather.

[0088] A front window brow 130 (also referred to as "window brow 130") may be at least partially disposed between the roof rails 106 and extend substantially orthogonally to the roof rails 106. A rear window brow 132 may be at least partially disposed between the roof rails 106 and extend substantially orthogonally to the roof rails 106. The front window brow 130 may be configured to join the driver-side roof rail 108 to the passenger-side roof rail 110 at the substantially forward A-pillar 104. The rear window brow 132 may be configured to join the roof rails 106 substantially rearward in the vehicle. The front window brow 130 and the rear window brow 132 may extend across the transverse width 122 of the roof 120. The front window brow 130 may be configured to join the roof 120 to a windshield 134.

[0089] In some aspects, as Figure 1 shown, the upper body structure 100 does not have a transverse reinforcement member. In some other aspects, the upper body structure 100 may optionally further include one or more transverse reinforcement members (not shown). The transverse reinforcement members may extend substantially orthogonally between the roof rails 106. The transverse reinforcement members may be longitudinally spaced as needed across the longitudinal length 112 to provide structural support and / or strength to the upper body structure 100.

[0090] In accordance with various aspects of the present disclosure, one or more components of the upper body structure 100 may be at least partially transparent (i.e., one or more regions may have a transparency greater than 0%). In some aspects, a portion of the upper body structure may be substantially opaque. In some aspects, the window brow 130 may be at least partially transparent, as described below in the discussion of Figures 2-6. In some aspects, the roof 120 may be at least partially transparent, as described below in the discussion of the attached Figures 7 - 9 figures. In some aspects, both the window brow 130 and the roof 120 may be at least partially transparent.

[0091] Referring Figure 2A to Figure 2B, the window brow 130 includes an elongate body 140. The elongate body 140 extends between a first side 142 and a second side 144 (also referred to as "sides 142, 144"). The elongate body 140 may include a front end 146 and a rear end 148 (also referred to as "ends 146, 148"). The sides 142, 144 may be configured to engage to the driver side roof rail 108 ( Figure 1 ) and the passenger side roof rail 110 ( Figure 1 ), respectively.

[0092] The windshield 134 ( Figure 1 ) may have a glass curvature (not shown) as needed to meet the vehicle's architecture design. The window brow 130 may have a curvature substantially similar to the glass curvature. The window brow 130 may have different geometries (e.g., shapes and / or curvatures), features (e.g., outer edges and / or constitutions), and configurations as needed to meet the required mechanical performance characteristics of the upper body structure 100.

[0093] The window brow 130 may be configured to engage the windshield 134 to the roof 120. In some aspects, as Figure 2B shown in Figure 2B, the window brow 130 may be directly engaged to the roof 120 by an adhesive 152. The adhesive 152 may be a transparent adhesive (e.g., a polyurethane adhesive). In some aspects, in addition to or in place of the adhesive, the window brow 130 may be directly engaged to the roof 120 by mechanical fasteners (not shown).

[0094] In some aspects (not shown), the window brow 130 may be directly engaged to both the windshield 134 and the roof 120. The front end 146 may be configured to engage to the windshield 134. The rear end 148 may be configured to engage to the roof 120.

[0095] Referring again Figure 2B, in some aspects, the window brow 130 may include a first component 154 and a second component 156 (also referred to as "components 154, 156"). The components 154, 156 may be formed separately (e.g., molded). The components 154, 156 may be joined to each other. In some aspects, the components 154, 156 are directly joined together by an adhesive (e.g., a transparent polyurethane adhesive) and / or welding. In some aspects, the window brow 130 may include more than two components, such as greater than or equal to three components, optionally greater than or equal to four components, or optionally greater than or equal to five components. In some other aspects, the window brow 130 may be an integral single component.

[0096] As described above, the window brow according to various aspects of the present disclosure may have customized strength and transparency. In some aspects, the window brow may have uniform strength and transparency. In some other aspects, the window brow may include multiple regions or zones having different strengths and transparencies. As an example, the window brow may have a first region having a first strength and a first transparency and a second region having a second strength and a second transparency different from the first strength and the first transparency. In some aspects, the window brow may include more than two regions having different strengths and / or transparencies, such as greater than or equal to three regions, optionally greater than or equal to five regions, optionally greater than or equal to ten regions, or optionally greater than or equal to fifteen regions. In some aspects, the window brow may include a gradient or multiple gradients of transparency and / or strength.

[0097] Referring to Figure 3A –3B, there is provided a window brow 300 of an upper body structure according to various aspects of the present disclosure. The upper body structure may be similar to Figure 1 the upper body structure 100 except for the window brow 300. Except as described below, the window brow 300 may be the same as Figure 1 the window brow 130 of

[0098] In some aspects, as Figure 3BAs best shown, the first region 302 includes a polymer 316 and a plurality of fibers 318 (e.g., high-strength fibers such as continuous fibers). As an example, the plurality of fibers 318 (also referred to as "first fibers 318") may be included at a volume percentage greater than or equal to about 10%. The first fibers 318 may be locally placed around the perimeter 320 of the window brow 300 (e.g., by a band). In some aspects, the first fibers 318 may be locally placed towards the front end 312 and the rear end 314. The first fibers 318 may form a plurality of tow-lines 326 extending between the first side 308 and the second side 310. The placement of the first fibers 318 on the perimeter 320 and / or the tow-lines 326 may form an interior region 328 that is substantially free of fibers.

[0099] The outer regions 304, 306 may include a polymer 316, the first plurality of first fibers 318, and a second plurality of fibers 330 (also referred to as "second fibers 330"). In some aspects, the second fibers 330 may be present at a volume percentage of the outer regions 304, 306 that is higher than the volume percentage of the first fibers 318 in the first region 302. In some aspects, the outer regions 304, 306 include a second polymer that is different from the polymer 316. The second polymer may optionally be opaque.

[0100] In some aspects, the first fibers 318 of the first region 302 may be discontinuous. The second fibers 330 of the outer regions 304, 306 may be continuous. The discontinuous fibers may be randomly oriented, oriented in the plane direction, or both randomly oriented and oriented in the plane direction. The continuous fibers may be oriented in the plane direction. In some aspects, the first fibers 318 may be continuous along the perimeter of the first region 302. The first fibers 318 and the second fibers 330 may be oriented the same or differently to meet the desired performance characteristics.

[0101] In some aspects, the window brow 300 may have a higher strength in the outer regions 304, 306 than the remainder of the window brow 300. At least a portion of the first region 302 may have a lower strength compared to the strength of the outer regions 304, 306.

[0102] In some aspects, the window brow 300 may have the highest transparency in the interior region 328 that is substantially free of fibers. The outer regions 304, 306 may have a lower transparency compared to the transparency of the interior region 328. In some aspects, due to the local placement of the first fibers 318 on the perimeter 320, the tow-lines 326 in the first region 302 may be substantially opaque.

[0103] Reference Figure 4A –4B, a window brow 400 of an upper body structure according to various aspects of the present disclosure is provided. The upper body structure may be similar to the upper body structure 100 of Figure 1 except for the window brow 400. Except as described below, the window brow 400 may be the same as the window brow 130 of Figure 1 -2. The window brow 400 may include a first outer region 402, a second outer region 404 (also referred to as "outer regions 402, 404"), and an inner region 406. The first outer region 402 may include a first side 408. The second outer region 404 may include a second side 410. The inner region 406 may be at least partially disposed between the first outer region 402 and the second outer region 404.

[0104] In some aspects, as best shown in Figure 4B , the outer regions 402, 404 and the inner region 406 may include a polymer 420 and a plurality of fibers 422. The fibers 422 of the inner region 406 may be locally formed around the perimeter 424 of the window brow 400. The inner region 406 may have a locally fiber-free area 426. The locally fiber-free area 426 may be coextensive with the inner region 406. In some aspects, the outer regions 402, 404 may include a higher volume percentage of fibers 422 compared to the inner region 406. The volume percentage of the fibers 422 in the first outer region 402 may be substantially equal to the volume percentage of the fibers 422 in the second outer region 404.

[0105] The outer regions 402, 404 may have a first strength and a first transparency. The inner region 406 may have a second strength and a second transparency. The second strength of the inner region 406 may be less than the first strength of the outer regions 402, 404. The inner region 406 may have a higher transparency than the outer regions 402, 404.

[0106] Reference Figure 5A –5B, a window brow 500 of an upper body structure according to various aspects of the present disclosure is provided. The upper body structure may be similar to the upper body structure 100 of Figure 1 except for the window brow 500. Except as described below, the window brow 500 may be the same as the window brow 400 of Figure 4A –4B. The window brow 500 may include a first outer region 502, a second outer region 504 (also referred to as "outer regions 502, 504"), and an inner region 506.

[0107] In some aspects, as Figure 5BAs best shown, the outer regions 502, 504 can be composed of a first polymer 520 and a first plurality of fibers 522. In some aspects, the volume percentage of the fibers 522 in the first outer region 502 is substantially equal to the volume percentage of the fibers 522 in the second outer region 504. The inner region 506 can be composed of a second polymer 530 without fibers. The second polymer 530 can be the same as or different from the first polymer 520.

[0108] The outer regions 502, 504 can have a higher strength than the inner region 506. In some aspects, the outer regions 502, 504 can be at least partially transparent. However, the inner region 506 can have a higher transparency than the outer regions 502, 504. In some aspects, the outer regions 502, 504 can be substantially opaque. In some aspects, the inner region 506 substantially without fibers can be substantially transparent.

[0109] Referring Figure 6 , a window brow 600 according to various aspects of the present disclosure is provided. Except as described below, the window brow 600 can be the same as the window brow 130 of Figure 1 -2. In some aspects, the window brow 600 can include a gradient 602. In some aspects, the gradient 602 can be a strength gradient. In some aspects, the gradient 602 can be a transparency gradient. In some aspects, the gradient 602 can be both a strength and a transparency gradient. In some aspects, the strength can increase as the transparency decreases, and the strength can decrease as the transparency increases.

[0110] In some aspects, the window brow 600 can include more than one gradient (e.g., gradients at different positions and / or in different directions), such as greater than or equal to two gradients, optionally greater than or equal to three gradients, optionally greater than or equal to four gradients, optionally greater than or equal to five gradients, or optionally greater than or equal to ten gradients. The additional gradients can have the same or different strength and / or transparency characteristics.

[0111] In some aspects, the gradient 602 can include a first gradient 604 extending from a first side 606 to a second side 608 (also referred to as "sides 606, 608"). As Figure 6 shown, the first gradient 604 can optionally include a first side gradient 610 that is mirror-imaged about the lateral center 611 (also referred to as "center 611") of the window brow 600 with a second side gradient 612. In some aspects, the gradient 602 can optionally include a second gradient 614 extending from a front end 616 to a rear end 618 (also referred to as "ends 616, 618"). The second gradient 614 can optionally include as Figure 6The front-end gradient 620 and the back-end gradient 622 shown in []. In some aspects, the gradient 602 may include both the first gradient 604 and the second gradient 614. In some aspects, the gradient 602 includes all the gradients 610, 612, 620, and 622.

[0112] In some aspects, the center 611 of the window lintel 600 may have a first intensity and a first transparency. The sides 606, 608 may have a second intensity higher than the first intensity and a second transparency lower than the first transparency. The second side 608 may have an intensity and a transparency substantially equal to those of the first side 606. The gradient 602 including the first side gradient 610 and the second side gradient 612 may have substantially the same rate of change between the intensity and transparency from the center 611 to the corresponding sides 606, 608. In some other aspects, the first side gradient 610 and the second side gradient 612 may have different rates of change between the intensity and transparency from the center 611 to the corresponding sides 606, 608.

[0113] In some aspects, the center 611 of the window lintel 600 may have a third intensity and a third transparency, and the ends 616, 618 may have a fourth intensity higher than the third intensity and a fourth transparency lower than the third transparency. The third intensity may be the same as the first intensity, and the third transparency may be similar to the first transparency. In some aspects, the fourth intensity may be similar to or the same as the second intensity. In some aspects, the fourth transparency may be similar to or the same as the second transparency. The back end 618 may have an intensity and a transparency substantially equal to those of the front end 616. The gradient 602 including the front-end gradient 620 and the back-end gradient 622 may have substantially the same rate of change between the intensity and transparency from the center 611 to the corresponding ends 616, 618. In some other aspects, the front-end gradient 620 and the back-end gradient 622 may have different rates of change between the intensity and transparency from the center 611 to the corresponding ends 616, 618.

[0114] In some other aspects, the window lintel may have only one of the first and second gradients 604, 614. In some other aspects, supplementing or substituting for the first and second gradients 604, 614, the window lintel may have one or more different gradients. Any configuration and arrangement of gradients can be utilized to achieve the desired intensity and transparency characteristics of the window lintel 600.

[0115] Referring to Figure 7 , the upper vehicle body structure 100 ( Figure 1) The roof 120 includes a body 702. The body 702 extends substantially laterally between a first side 704 and a second side 706 (also referred to as "sides 704, 706"). The sides 704, 706 may be configured to connect each roof rail 106. The body 702 may extend substantially longitudinally between a front end 708 and a rear end 710 (also referred to as "ends 708, 710"). The front end 708 may be configured to engage the window brow 130. In some aspects, the front end 708 may be configured to directly engage the window brow 130. The rear end 710 may be configured to engage the rear window brow 132. In some aspects, the rear end 710 may be configured to directly engage the rear window brow 132.

[0116] In various aspects, the roof according to various aspects of the present disclosure may have customized strength and transparency. In some aspects, the roof may have uniform strength and transparency. In some other aspects, the roof may include a plurality of regions or zones having different strengths and transparencies. As an example, the roof may have a first region having a first strength and a first transparency, and a second region having a second strength and a second transparency different from the first strength and the first transparency. The roof may optionally include more than two regions having different strengths and transparencies, such as optionally greater than or equal to three regions, optionally greater than or equal to five regions, optionally greater than or equal to ten regions, or optionally greater than or equal to fifteen regions. In some aspects, the roof may include a gradient or a plurality of gradients of transparency.

[0117] Referring to Figure 8 , there is provided a roof 800 of an upper body structure according to various aspects of the present disclosure, and the upper body structure may be similar to Figure 1 the upper body structure 100 except for the roof 800. Except as described below, the roof 800 may be the same as Figure 1 and Figure 7 the roof 120. In some aspects, the roof 800 may include a first region 802, a second region 804, a third region 806, and a fourth region 808 (also referred to as "regions 802, 804, 806, 808"). In some aspects, the transparency and strength of each of the regions 802, 804, 806, 808 may be substantially the same.

[0118] In some other aspects, the transparency and / or intensity of each of regions 802, 804, 806, 808 can be different. For example, the first region 802 can have a first transparency that is greater than or equal to about 10% to less than or equal to about 20% (e.g., about 15%). The second region 804 can have a second transparency that is greater than or equal to about 40% to less than or equal to about 10% (e.g., about 4%). The third region 806 can have a third transparency that is greater than or equal to about 20% to less than or equal to about 40% (e.g., about 30%). The fourth region 808 can have a transparency that is greater than or equal to about 50% to less than or equal to about 70% (e.g., about 60%).

[0119] In some other aspects, all or a portion of regions 802, 804, 806, 808 can be similar or identical to other regions 802, 804, 806, 808 of roof 800 in terms of transparency and / or intensity. In one example, the first and second regions 802, 804 have the same or similar transparency and / or intensity, and the third and fourth regions 806, 808 have the same or similar transparency and / or intensity. In some other aspects, all or a portion of the regions can have different geometries (e.g., shape, size, and / or position) and / or arrangements. Any combination of regions including any combination of intensity and transparency can be utilized and arranged to provide the desired strength and transparency characteristics of the upper body assembly.

[0120] Referring Figure 9 , a roof 900 is provided in accordance with various aspects of the present disclosure. Except as described below, the roof 900 can be the same as Figure 1 and Figure 7 the roof 120. In some aspects, the roof 900 can include a gradient 902. In some aspects, the gradient 902 can be an intensity gradient. In some aspects, the gradient 902 can be a transparency gradient. In some aspects, the gradient 902 can be an intensity and transparency gradient. In some aspects, the intensity can increase as the transparency decreases, and the intensity can decrease as the transparency increases.

[0121] In some aspects, the roof 900 can include more than one gradient (e.g., gradients at different locations and / or in different directions), such as greater than or equal to two gradients, optionally greater than or equal to three gradients, optionally greater than or equal to four gradients, optionally greater than or equal to five gradients, or optionally greater than or equal to ten gradients. The additional gradients can have the same or different intensity characteristics and / or transparency characteristics.

[0122] In some aspects, the gradient 902 can include a first gradient 904 that extends from a first side 906 to a second side 908 (also referred to as "sides 906, 908"). AsFigure 9 As shown, the first gradient 904 may optionally include a first side gradient 910 that is a mirror image of a second side gradient 912 about the lateral center 911 (also referred to as "center 911") of the roof 900. In some aspects, the gradient 902 may optionally include a second gradient 914 that extends from a front end 916 to a rear end 918 (also referred to as "ends 916, 918"). The second gradient 914 may optionally include a front end gradient 920 and a rear end gradient 922 as shown in Figure 9 . In some aspects, the gradient 902 may include both the first gradient 904 and the second gradient 914. In some aspects, the gradient 902 includes all of the gradients 910, 912, 920, and 922.

[0123] In some aspects, the center 911 of the roof 900 may have a first strength and a first transparency. The sides 906, 908 may have a second strength that is higher than the first strength and a second transparency that is lower than the first transparency. The second side 908 may have a strength and transparency that are substantially equal to those of the first side 906. The gradient 902 including the first side gradient 910 and the second side gradient 912 may have a substantially equal rate of change between the strength and transparency at the center 911 and the respective sides 906, 908. In some other aspects, the first side gradient 910 and the second side gradient 912 may have different rates of change between the strength and transparency at the center 911 and the respective sides 906, 908.

[0124] In some aspects, the center 911 of the roof 900 may have a third strength and a third transparency, and the ends 916, 918 may have a fourth strength that is higher than the third strength and a fourth transparency that is lower than the third transparency. The third strength may be the same as the first strength, and the third transparency may be similar to the first transparency. In some aspects, the fourth strength may be similar to or the same as the second strength. In some aspects, the fourth transparency may be similar to or the same as the second transparency. The rear end 918 may have a strength and transparency that are substantially equal to those of the front end 916. The gradient 902 including the front end gradient 920 and the rear end gradient 922 may have a substantially equal rate of change between the strength and transparency at the center 911 and the respective ends 916, 918. In some other aspects, the front end gradient 920 and the rear end gradient 922 may have different rates of change between the strength and transparency at the center 911 and the respective ends 916, 918.

[0125] In some other aspects, the vehicle roof may have only one of the first and second gradients 904, 914. In some other aspects, supplementary or alternative to the first and second gradients 904, 914, the vehicle roof may have one or more different gradients. Any configuration and arrangement of the gradients can be utilized to achieve the desired strength and transparency characteristics of the vehicle roof 900.

[0126] The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. The individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in selected embodiments, even if not explicitly shown or described. It can also be changed in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

[0127] This application may include the following embodiments.

[0128] 1. A window brow for a vehicle upper body structure, comprising:

[0129] An elongate body extending between a first side and a second side, the elongate body comprising a polymer and a plurality of fibers, the elongate body comprising,

[0130] A front end configured to be joined to a windshield,

[0131] A rear end configured to be joined to a vehicle roof, wherein at least a portion of the elongate body has a transparency of greater than or equal to about 4%.

[0132] 2. The window brow according to embodiment 1, wherein the transparency is greater than or equal to about 50% to less than or equal to about 99%.

[0133] 3. The window brow according to embodiment 1, wherein the volume percentage of the plurality of fibers is greater than or equal to about 5 vol% to less than or equal to about 35 vol%.

[0134] 4. The window brow according to embodiment 1, wherein the local tensile strength of the elongate body is greater than or equal to about 40 MPa to less than or equal to about 1000 MPa.

[0135] 5. The window brow according to embodiment 1, wherein the window brow comprises a first component and a second component joined to the first component.

[0136] 6. The window brow according to embodiment 1, wherein at least a portion of the elongate body is fiber-free.

[0137] 7. The window brow according to embodiment 1, wherein the plurality of fibers are dispersed substantially uniformly throughout the elongate body.

[0138] 8. The window lintel according to Scheme 1, wherein the elongated body comprises,

[0139] a first region having a first transparency and a first tensile strength, and

[0140] a second region having a second transparency and a second tensile strength, the second transparency being greater than the first transparency and the second tensile strength being less than the first tensile strength.

[0141] 9. The window lintel according to Scheme 8, wherein:

[0142] the first region includes a first outer region containing the first side and a second outer region containing the second side, and

[0143] the second region is at least partially disposed between the first outer region and the second outer region.

[0144] 10. The window lintel according to Scheme 9, wherein:

[0145] the second region contains a polymer substantially free of fibers, and

[0146] the first region contains the polymer and the plurality of fibers.

[0147] 11. The window lintel according to Scheme 8, wherein:

[0148] the first region includes the rear end, and

[0149] the second region includes the front end.

[0150] 12. The window lintel according to Scheme 1, wherein the elongated body defines a transparency gradient.

[0151] 13. The window lintel according to Scheme 12, wherein the transparency gradient comprises a plurality of transparency gradients.

[0152] 14. The window lintel according to Scheme 13, wherein the plurality of transparency gradients includes a first gradient and a second gradient having a rate of change substantially equal to that of the first gradient.

[0153] 15. The window lintel according to Scheme 1, wherein the polymer is selected from: epoxy resin, polyurethane (PUR), polycarbonate (PC), polymethyl methacrylate (PMMA), polyethylene terephthalate (PET), polyacrylate (acrylic), polyamide (PA), its copolymers, and combinations thereof.

[0154] 16. The window lintel according to Scheme 1, wherein the plurality of fibers are selected from: glass fiber, carbon fiber, basalt fiber, aramid fiber, polyethylene fiber, polypropylene fiber, natural fiber, or any combination thereof.

[0155] 17. The window lintel according to Scheme 16, wherein:

[0156] the plurality of fibers have a shape selected from: cylindrical, flat, or both cylindrical and flat, and

[0157] the plurality of fibers have an orientation selected from: continuous in the first plane direction, discontinuous in the first plane direction, discontinuous in multiple directions, or any combination thereof.

[0158] 18. The window lintel according to Scheme 1, wherein the plurality of fibers include a plurality of continuous fibers and a plurality of discontinuous fibers.

[0159] 19. The window lintel according to Scheme 1, wherein the elongated body further comprises an additive selected from: ultraviolet (UV) absorber, quencher, hindered amine light stabilizer (HALS), or a combination thereof.

[0160] 20. An upper body structure, comprising:

[0161] a first side structure;

[0162] a second side structure;

[0163] a roof;

[0164] a window lintel; and

[0165] the window lintel includes an elongated body extending between the first side and the second side, the elongated body comprising:

[0166] a polymer and a plurality of fibers,

[0167] a front end configured to be joined to a windshield,

[0168] a rear end configured to be joined to the roof,

[0169] the first side is configured to be joined to the first side structure,

[0170] the second side is configured to be joined to the second side structure, wherein at least a portion of the elongated body has a transparency greater than or equal to about 4%.

Claims

1. A window brow for a vehicle upper body structure, comprising: An elongated body extending between a first side and a second side, the elongated body comprising a polymer and a plurality of fibers, the elongated body comprising, A front end configured to be joined to a windshield, A rear end configured to be joined to a vehicle roof, wherein at least a portion of the elongated body has a transparency of greater than or equal to 4%, Wherein the elongated body includes, A first region having a first transparency and a first tensile strength, and A second region having a second transparency and a second tensile strength; The second transparency is greater than the first transparency and the second tensile strength is less than the first tensile strength, The first region includes a first outer region including the first side and a second outer region including the second side, and the second region is at least partially disposed between the first outer region and the second outer region.

2. The window brow according to claim 1, wherein the first region includes the rear end and the second region includes the front end.

3. The window brow according to claim 1, wherein the transparency is greater than or equal to 50% to less than or equal to 99%.

4. The window brow according to claim 1, wherein the volume percentage of the plurality of fibers is greater than or equal to 5% by volume to less than or equal to 35% by volume.

5. The window brow according to claim 1, wherein the local tensile strength of the elongated body is greater than or equal to 40 MPa to less than or equal to 1000 MPa.

6. The window brow according to claim 1, wherein the window brow comprises a first component and a second component joined to the first component.

7. The window brow according to claim 1, wherein at least a portion of the elongated body is fiber-free.

8. The window brow according to claim 1, wherein the plurality of fibers are uniformly dispersed throughout the elongated body.

9. The window brow according to claim 1, wherein: The second region contains a polymer without fibers, and the first region contains the polymer and the plurality of fibers.

10. The window brow according to claim 1, wherein the elongated body defines a transparency gradient.

11. The window brow according to claim 10, wherein the transparency gradient comprises a plurality of transparency gradients.

12. The window lintel according to claim 11, wherein the plurality of transparency gradients includes a first gradient and a second gradient having a rate of change equal to that of the first gradient.

13. The window lintel according to claim 1, wherein the polymer is selected from: epoxy resin, polyurethane, polycarbonate, polymethyl methacrylate, polyethylene terephthalate, polyacrylate, polyamide.

14. The window lintel according to claim 1, wherein the plurality of fibers is selected from: glass fiber, carbon fiber, basalt fiber, aramid fiber, polyethylene fiber, polypropylene fiber, natural fiber, or any combination thereof.

15. The window lintel according to claim 14, wherein: the plurality of fibers has a shape selected from: cylindrical, flat, or both cylindrical and flat, and the plurality of fibers has an orientation selected from: continuous in a first planar direction, discontinuous in a first planar direction, discontinuous in a plurality of directions, or any combination thereof.

16. The window lintel according to claim 1, wherein the plurality of fibers includes a plurality of continuous fibers and a plurality of discontinuous fibers.

17. The window lintel according to claim 1, wherein the elongated body further comprises an additive selected from: ultraviolet absorber, quencher, hindered amine light stabilizer.

18. An upper body structure, comprising: First side structure; Second side structure; Roof; Window brow; and the window brow includes an elongated body extending between a first side and a second side, the elongated body comprising: a polymer and a plurality of fibers, a front end configured to be joined to a windshield, a rear end configured to be joined to the roof, the first side configured to be joined to the first side structure, the second side configured to be joined to the second side structure, wherein at least a portion of the elongated body has a transparency of greater than or equal to 4%, wherein the elongated body includes, a first region having a first transparency and a first tensile strength, and a second region having a second transparency and a second tensile strength; the second transparency is greater than the first transparency and the second tensile strength is less than the first tensile strength, the first region includes a first outer region including the first side and a second outer region including the second side, and the second region is at least partially disposed between the first outer region and the second outer region.

19. The upper body structure according to claim 18, wherein the first region includes the rear end and the second region includes the front end.

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