Transparent composite material for vehicle roofs

Abstract

This invention discloses a transparent composite material for vehicle roofs. The disclosure provides a roof for a vehicle's upper body structure. The roof includes a body extending between a first and second side and between a front end and a rear end. The front end is configured to be integrated with a window lintel. The body comprises a polymer and multiple fibers. At least a portion of the body has a transparency of greater than or equal to about 4%.

Description

Technical Field

[0001] This invention discloses a roof for the upper main structure of a vehicle and an upper main structure. Background Technology

[0002] This disclosure relates to a transparent component for the upper body structure of a vehicle.

[0003] This section provides background information relating to this disclosure, which is not necessarily prior art.

[0004] The vehicle upper body assembly provides structural support and mounting locations for other vehicle components. Improving the strength and structural performance of the vehicle upper body assembly is advantageous. However, it is also advantageous for components in the automobile or other vehicle to be lightweight to improve efficiency. Furthermore, it is advantageous for components of the structural assembly to be at least partially transparent to improve occupant visibility and / or aesthetics. Therefore, it is advantageous for vehicle components in the structural assembly to exhibit sufficient strength during normal service while minimizing component weight and increasing occupant visibility. Summary of the Invention

[0005] This section provides a general overview of this disclosure and is not a full disclosure of its entire scope or all its features.

[0006] This disclosure relates to a transparent composite material roof and a vehicle upper body assembly including the transparent roof.

[0007] In various aspects, this disclosure provides a roof for a vehicle upper body structure. The roof includes a body extending between a first side and a second side and between a front end and a rear end. The body comprises a polymer and multiple fibers. The front end is configured to be integrated into a header. At least a portion of the body has a transparency of greater than or equal to about 4%.

[0008] In one respect, the roof has a transparency of approximately 50% to approximately 99%.

[0009] In one respect, the volume percentage of multiple fibers is greater than or equal to about 5% by volume and less than or equal to about 35% by volume.

[0010] In one respect, the local tensile strength of the body is greater than or equal to about 40 MPa to less than or equal to about 1000 MPa.

[0011] In one respect, at least a portion of the body does not contain fibers.

[0012] In one respect, a large number of fibers are distributed substantially uniformly throughout the entire body.

[0013] In one aspect, the 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, a first region comprises a first volume percentage of fibers. A second region comprises a second volume percentage of fibers. The first volume percentage of fibers is greater than the second volume percentage of fibers.

[0015] In one respect, a first region defines a first thickness. A second region defines a second thickness. The first thickness is greater than the second thickness.

[0016] In one aspect, the body also includes a third region with third transparency and third tensile strength.

[0017] In one aspect, the body also includes a fourth region having a fourth transparency and a fourth tensile strength.

[0018] In one respect, the subject limits the transparency gradient.

[0019] In one respect, transparency gradients include multiple transparency gradients.

[0020] In one aspect, multiple transparency gradients include a first gradient and a second gradient. The second gradient has a rate of change that is substantially equal to that of the first gradient.

[0021] In one aspect, the polymer is selected from: epoxy resins, polyurethane (PUR), polycarbonate (PC), polymethyl methacrylate (PMMA), polyethylene terephthalate (PET), polyacrylates (acrylic), polyamides (PA) (e.g., nylon), copolymers thereof, and combinations thereof.

[0022] In one respect, the multiple fibers are selected from: glass fiber, carbon fiber, basalt fiber, aramid fiber, polyethylene fiber, polypropylene fiber, natural fiber, or any combination thereof.

[0023] 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 multiple directions, or any combination thereof.

[0024] In one respect, multiple fibers include multiple continuous fibers and multiple discontinuous fibers.

[0025] In one aspect, the body also includes additives selected from: ultraviolet (UV) absorbers, quenchers, hindered amine light stabilizers (HALS), or combinations thereof.

[0026] In various aspects, this disclosure provides a superstructure. The superstructure includes a first side structure, a second side structure, a window lintel, and a roof. The roof includes a body extending between the first and second sides and between a front end and a rear end. The front end is configured to be attached to the window lintel. The first side is configured to be attached to the first side structure. The second side is configured to be attached to the second side structure. The body comprises a polymer and multiple fibers. At least a portion of the body has a transparency of greater than or equal to about 4%.

[0027] The present invention discloses the following embodiments: 1. A roof for the upper main structure of a vehicle, comprising:

[0028] The body extends between a first side and a second side and between a front end and a rear end, the body comprising,

[0029] Polymers and multiple fibers,

[0030] The front end is configured to be integrated into the header, wherein at least a portion of the main body has a transparency of about 4%.

[0031] 2. The roof according to embodiment 1, wherein the transparency is greater than or equal to about 50% and less than or equal to about 99%.

[0032] 3. The roof according to embodiment 1, wherein the volume percentage of the plurality of fibers is greater than or equal to about 5% by volume and less than or equal to about 35% by volume.

[0033] 4. The roof according to embodiment 1, wherein the local tensile strength of the main body is greater than or equal to about 40 MPa to less than or equal to about 1000 MPa.

[0034] 5. The roof according to embodiment 1, wherein at least a portion of the main body is fiber-free.

[0035] 6. The roof according to embodiment 1, wherein the plurality of fibers are substantially uniformly distributed throughout the body.

[0036] 7. The vehicle roof according to embodiment 1, wherein the main body includes,

[0037] A first region having first transparency and first tensile strength, and

[0038] A second region having a second transparency and a second tensile strength, wherein the second transparency is greater than the first transparency and the second tensile strength is less than the first tensile strength.

[0039] 8. The roof according to implementation scheme 7, wherein:

[0040] The first region comprises a first volume percentage of fibers.

[0041] The second region includes a second volume percentage of fibers, and

[0042] The first volume percentage of the fiber is greater than the second volume percentage of the fiber.

[0043] 9. The roof according to implementation scheme 7, wherein:

[0044] The first region defines the first thickness.

[0045] The second region defines the second thickness, and

[0046] The first thickness is greater than the second thickness.

[0047] 10. The roof according to embodiment 7, wherein the body further includes a third region having a third transparency and a third tensile strength.

[0048] 11. The roof according to embodiment 7, wherein the body further includes a fourth region having a fourth transparency and a fourth tensile strength.

[0049] 12. The roof according to embodiment 1, wherein the main body defines a transparency gradient.

[0050] 13. The roof according to embodiment 12, wherein the transparency gradient includes a plurality of transparency gradients.

[0051] 14. The roof according to embodiment 13, wherein the plurality of transparency gradients include a first gradient and a second gradient, the second gradient having a rate of change substantially equal to that of the first gradient.

[0052] 15. The roof according to embodiment 1, wherein the polymer is selected from: epoxy resin, polyurethane (PUR), polycarbonate (PC), polymethyl methacrylate (PMMA), polyethylene terephthalate (PET), polyacrylate (acrylic), polyamide (PA), copolymers thereof, and combinations thereof.

[0053] 16. The roof according to embodiment 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.

[0054] 17. The vehicle roof according to implementation scheme 16, wherein:

[0055] The plurality of fibers have shapes selected from: cylindrical, flat, or both cylindrical and flat, and

[0056] The fibers have an orientation selected from the following: continuous in a first planar direction, discontinuous in a first planar direction, discontinuous in multiple directions, or any combination thereof.

[0057] 18. The roof according to embodiment 1, wherein the plurality of fibers comprises a plurality of continuous fibers and a plurality of discontinuous fibers.

[0058] 19. The roof according to embodiment 1, wherein the main body further includes an additive selected from: ultraviolet (UV) absorbers, quenchers, hindered amine light stabilizers (HALS), or combinations thereof.

[0059] 20. A superstructure, comprising:

[0060] First side structure;

[0061] Second side structure;

[0062] Window header;

[0063] The roof; and

[0064] The roof includes a body extending between a first side and a second side and between a front end and a rear end, the body comprising,

[0065] Polymers and multiple fibers,

[0066] The front end, configured to be attached to the header,

[0067] The first side is configured to be attached to the first side structure.

[0068] The second side is configured to be integrated into the second side structure, wherein at least a portion of the body has a transparency of about 4%.

[0069] Further applications will become apparent from the description provided herein. The descriptions and specific examples in this invention are for illustrative purposes only and are not intended to limit the scope of this disclosure. Attached Figure Description

[0070] The accompanying drawings described herein are for illustrative purposes only, for the purposes of selecting embodiments and not all possible implementations, and are not intended to limit the scope of this disclosure.

[0071] Figure 1 It is a perspective view of the upper main structure of the vehicle, including the window lintels and the roof, according to various aspects of this disclosure;

[0072] Figure 2 Based on all aspects of this disclosure Figure 1 A top view of the car's roof;

[0073] Figure 3 This is a top view of another vehicle roof according to various aspects of this disclosure;

[0074] Figure 4 This is a top view of another vehicle roof according to various aspects of this disclosure;

[0075] Figure 5A Based on all aspects of this disclosure Figure 1 A top view of the window header;

[0076] Figure 5B yes Figure 1 The upper main structure along Figure 1 A partial sectional view of line 5B-5B;

[0077] Figure 6A This is a top view of another window in accordance with various aspects of this disclosure;

[0078] Figure 6B yes Figure 6A A schematic diagram of a window lintel;

[0079] Figure 7A This is a top view of another window in accordance with various aspects of this disclosure;

[0080] Figure 7B yes Figure 7A A schematic diagram of a window lintel;

[0081] Figure 8A This is a top view of another window in accordance with various aspects of this disclosure;

[0082] Figure 8B yes Figure 8A A diagram of a window lintel; and

[0083] Figure 9 This is another perspective view of various aspects of this disclosure.

[0084] In the various views of the accompanying drawings, the corresponding reference numerals denote the respective components. Detailed Implementation

[0085] Exemplary embodiments are provided to make this disclosure complete and to fully communicate its scope to those skilled in the art. Numerous specific details, such as examples of specific components, parts, apparatuses, and methods, are set forth to provide a full understanding of embodiments of this disclosure. It will be apparent to those skilled in the art that specific details are not required, that exemplary embodiments may be presented in many different forms, and that none of them should be construed as limiting the scope of this disclosure. In some exemplary embodiments, well-known methods, well-known apparatus structures, and well-known techniques are not described in detail.

[0086] The terminology used herein is for the purpose of describing particular exemplary embodiments only and is not intended to be limiting. Unless the context clearly indicates otherwise, the singular forms “a,” “an,” and “the” are intended to include the plural forms as used herein. The terms “comprising,” “including,” “covering,” and “having” are concurrent and thus specify the presence of the stated features, elements, compositions, steps, integers, operations, and / or components, but do not exclude the presence or inclusion of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. Although the open-ended term “comprising” should be understood as a non-limiting term used to describe and claim the various embodiments described herein, in some respects it may be understood alternatively to more restrictive and limiting terms such as “consisting of” or “substantially consisting of.” Thus, for any given embodiment recounting a composition, material, component, element, feature, integer, operation, and / or method step, this disclosure also specifically includes embodiments consisting of or substantially consisting of such recounted compositions, materials, components, elements, features, integers, operations, and / or method steps. In the case of “consisting of…”, the alternative embodiments exclude any additional compositions, materials, components, elements, features, integers, operating and / or method steps. In the case of “essentially composed of…”, any additional compositions, materials, components, elements, features, integers, operating and / or method steps that substantially affect the essential and novel characteristics are excluded from such embodiments. However, any compositions, materials, components, elements, features, integers, operating and / or method steps that do not substantially affect the essential and novel characteristics may be included in the embodiments.

[0087] Any methods, procedures, and operations described herein should not be construed as necessarily requiring them to be performed in the specific order discussed or illustrated, unless explicitly stated as such. It should also be understood that, unless otherwise stated, additional or alternative steps may be employed.

[0088] When a component, element, or layer is referred to as being “on,” “engaged,” “connected,” or “bonded” to another component or layer, it may be directly engaged, connected, or bonded to the other component, element, or layer, or an intermediary element or layer may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged,” “directly connected,” or “directly bonded” to another component or layer, an intermediary element or layer may not be present. Other terms used to describe relationships between elements should be interpreted similarly (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and / or” includes any and all combinations of one or more of the related enumerated items.

[0089] 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 stated. These terms may be used only to distinguish one step, element, component, region, layer, or section from another. Unless the context clearly indicates otherwise, terms such as “first,” “second,” and other numerical terms used herein do not imply order or sequence. Therefore, 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.

[0090] For ease of description, spatially or temporally relative terms such as “before,” “after,” “inner,” “outer,” “below,” “below,” “lower,” “above,” “upper,” etc., may be used herein to describe the relationship of one element or feature as shown in the accompanying drawings to other elements or features(s). In addition to the orientations shown in the accompanying drawings, spatially or temporally relative terms may be intended to cover different orientations of the apparatus or system during use or operation.

[0091] Throughout this disclosure, numerical values ​​represent approximate measurements or range limits to cover slight deviations from a given value and embodiments that substantially have the mentioned value as well as embodiments that precisely have the mentioned value. Except in the detailed description of the working examples provided at the end, all numerical values ​​of parameters (e.g., quantities or conditions) in this specification (including the appended claims) should be understood to be modified in all cases by the term “about,” regardless of whether “about” actually precedes the numerical value. “About” means that the numerical value allows for a certain degree of slight imprecision (approaching the exact value to a certain extent; substantially or reasonably approximating the value; almost). If the imprecision provided by “about” is not otherwise understood in this ordinary sense in the art, then “about” as used herein refers to at least a deviation that can be caused by ordinary methods of measuring and using such parameters. For example, “about” may include deviations 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 respects optionally less than or equal to 0.1%.

[0092] In addition, the disclosure of the range includes disclosure of all values ​​throughout the range and disclosure of further subdivisions of the range, including disclosure of endpoints and subranges given by the range.

[0093] Exemplary embodiments will now be described more fully with reference to the accompanying drawings.

[0094] Structural assemblies can be used in vehicles to provide structural support and / or mounting locations for other vehicle components. One structural assembly for a superstructure may include multiple superstructure components, such as a front window lintel, rear window lintel, roof, driver's side roof beam, passenger side roof beam, and multiple pairs of structural pillars. The roof may extend substantially rearward within the vehicle and connect the driver's side roof beam to the passenger side roof beam. The window lintel assembly connects the driver's side roof beam to the passenger side roof beam. The window lintel assembly supports both the roof and the windshield and connects the roof to the windshield. Advantageously for the superstructure, high stiffness and strength are present in localized areas near the roof beams and structural pillars, particularly near the junctions of the window lintel and roof beams, and the junctions of the roof and roof beams.

[0095] Some structural components, including upper body components, may be made of metals such as steel. Some structural components may be made of opaque fiber-reinforced composite materials.

[0096] Some structural components, including upper body components, may be constructed of glass (e.g., sunroof). Some structural components may be constructed of laminated composite materials. Some structural assemblies comprising glass and / or laminated composite components may be integrally formed with additional reinforcing components to achieve desired strength and mechanical properties.

[0097] The upper body component can be opaque, thus reducing or suppressing occupant visibility in the corresponding vehicle area. Some upper body structures can be complex to assemble due to the large number of reinforcing components. Furthermore, structural components including metal and / or glass components can be heavy, leading to reduced fuel efficiency and / or battery range in the vehicle.

[0098] In various aspects, this disclosure provides a transparent component (also referred to as a "superstructure assembly") for a vehicle upper body structure. The upper body assembly can be configured to provide structural support, occupant visibility, and protection of occupants from rain, snow, ultraviolet (UV) light, and other elements. As used herein, transparent means that at least a portion of the assembly has a transparency greater than 0%. The upper body assembly may be constructed of or comprise a fiber-reinforced composite material. The fiber-reinforced composite material may include a polymer and multiple fibers. In some aspects, the transparent assembly may include a first region having relatively high strength and relatively low transparency, and a second region having relatively low strength and relatively high transparency. In some aspects, the transparent assembly may include a window lintel (e.g., a front window lintel and / or a rear window lintel), a roof, or a window lintel and a roof. In some aspects, this disclosure provides an upper body structure comprising a window lintel and a roof, wherein at least one of the window lintel and the roof (and optionally both the window lintel and the roof) is transparent.

[0099] The fiber-reinforced composite superstructure assembly according to various aspects of this disclosure may be lighter than a metal and / or glass superstructure assembly. This lighter weight superstructure assembly can improve vehicle fuel efficiency and / or battery range. In some aspects, the superstructure assembly may include multiple regions with customized strength and transparency. For example, regions expected to withstand higher loads may have high strength (e.g., near the joints between the superstructure assembly and the roof beam and / or pillars). Regions expected to withstand lower loads (e.g., near the vehicle's centerline) may 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 may therefore exhibit higher transparency than the higher-strength regions.

[0100] In various respects, the stiffness and strength of the at least partially transparent superstructure components achieve the desired mechanical properties of the superstructure. In some respects, the at least partially transparent components may not require additional reinforcing components. In some respects, the local tensile strength (tensile stress in at least one region of the upper body component) of the upper body component may 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 respects, the tensile modulus of the upper main body component may 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 main component may 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.

[0101] The upper body assembly can be configured to achieve the 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 may 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.

[0102] In all respects, a transparent upper body assembly improves occupant visibility compared to a substantially opaque upper body assembly. At least a portion (or optionally substantially the entire transparent upper body assembly) of the transparent upper body assembly may have a transparency or average light transmittance of greater than or equal to about 4% and less than or equal to about 99%, or optionally greater than or equal to about 50% and less than or equal to about 99%. In some respects, the portion may have a transparency of about 4%, optionally about 10%, optionally about 15%, optionally about 20%, optionally about 25%, optionally about 30%, optionally about 35%, optionally about 40%, optionally about 45%, optionally about 50%, optionally about 55%, optionally about 60%, optionally about 65%, optionally about 70%, optionally about 75%, optionally about 80%, optionally about 85%, optionally about 90%, or optionally about 95%. In some respects, transparency is less than or equal to approximately 100%, optionally less than or equal to approximately 90%, optionally less than or equal to approximately 80%, optionally less than or equal to approximately 70%, optionally less than or equal to approximately 60%, optionally less than or equal to approximately 50%, optionally less than or equal to approximately 40%, optionally less than or equal to approximately 30%, optionally less than or equal to approximately 20%, or optionally less than or equal to approximately 10%.

[0103] In one example, the transparent upper body component comprises two areas. The first area has a first transparency of greater than or equal to 0% to less than or equal to about 20%. The second area has a second transparency of greater than or equal to about 20% to less than or equal to about 99%.

[0104] In another example, the transparent upper body component includes a first region having a first transparency of about 0% to about 4%. The upper body component also includes a second region having a second transparency of about 5% to about 99%.

[0105] The upper body component according to various aspects of this disclosure may include a polymer and multiple fibers. The polymer may be a thermosetting polymer or a thermoplastic polymer that is substantially transparent in the absence of fibers. In some aspects, the polymer may be a thermosetting polymer selected from: benzoxazine, bis-maleimide (BMI), cyanate esters, epoxy resins, phenolic resins (PF), polyacrylates (acrylic), polyimide (PI), unsaturated polyesters, polyurethanes (PUR), vinyl esters, siloxanes, copolymers thereof, and combinations thereof. In some aspects, the polymer may be a thermoplastic polymer selected from the following: polyethyleneimine (PEI), polyamide-imide (PAI), polyamide (PA) (e.g., 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), polyaryl etherketone (PAEK), polyetherketoneketone (PEKK), copolymers thereof, and combinations thereof. In some aspects, the upper body component may include more than one polymer. In some aspects, the upper body component may also include a substantially opaque polymer, for example, in areas of lower transparency or no transparency.

[0106] In some respects, multiple fibers (also referred to as “fibers”) may have lengths and / or orientations that satisfy the desired strength of the vehicle superstructure assembly. In some respects, the fibers may be continuous and oriented in a substantially uniform direction, discontinuous and oriented in a substantially uniform 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 substantially complete load transfer from the fibers to the polymer matrix can occur when the superstructure assembly is exposed to tensile or compressive stress. The critical length is material-dependent. In one example, for glass fibers in an epoxy resin matrix, the critical length is about 97.5 μm. The substantially uniform orientation may be in a first planar direction, such that the superstructure assembly has increased strength in the first planar direction. The superstructure assembly may optionally include more than one fiber orientation to obtain the desired mechanical strength and / or stiffness.

[0107] In some respects, the fiber may have a substantially cylindrical shape, a substantially flat shape, or both a substantially cylindrical and substantially flat shape. The fiber shape may be defined by its length, width, and thickness. The fiber length may be greater than or equal to the critical length. In some respects, the length is approximately 10 times the effective diameter of the fiber.

[0108] The substantially flat shape can be defined by a first dimension, a second dimension, and a third dimension (e.g., thickness). In some respects, the third dimension is smaller than the first and / or second dimensions. In some respects, the third dimension may be less than or equal to about 25% of the first and / or second dimensions, optionally less than or equal to about 20% of the first and / or second dimensions, optionally less than or equal to about 15% of the first and / or second dimensions, or optionally less than or equal to about 10% of the first and / or second dimensions. In one example, the substantially 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.

[0109] In some aspects, the upper body assembly may include continuous fibers having a substantially cylindrical shape and being oriented substantially in a first planar direction. In some aspects, the upper body assembly may include discontinuous fibers having a substantially cylindrical shape and being oriented substantially in a first planar direction. In some aspects, the upper body assembly may include discontinuous fibers optionally having a substantially flat shape and being oriented substantially in a first planar direction.

[0110] Suitable fiber materials may include carbon fibers (e.g., carbon black, carbon nanotubes, talc, fibers derived from polyacrylonitrile and / or pitch precursors), glass fibers (e.g., glass fibers, quartz), basalt fibers, aramid fibers (e.g., KEVLAR®, polyphenylene benzobisoxazole (PBO)), polyethylene fibers (e.g., high-strength ultra-high molecular weight (UHMW) polyethylene), polypropylene fibers (e.g., high-strength polypropylene), natural fibers (e.g., cotton, flax, cellulose, spider silk), and combinations thereof, as examples.

[0111] In some aspects, the upper body component may contain fibers in an amount greater than or equal to 5 volume percent, optionally greater than or equal to about 10 volume percent, optionally greater than or equal to about 20 volume percent, optionally greater than or equal to about 30 volume percent, optionally greater than or equal to about 35 volume percent, or optionally greater than or equal to about 40 volume percent. In some aspects, the upper body component may contain fibers in an amount less than or equal to about 60 volume percent, optionally less than or equal to about 50 volume percent, optionally less than or equal to about 40 volume percent, or optionally less than or equal to about 30 volume percent.

[0112] In various aspects, the strength and transparency of the upper body assembly can be customized to achieve desired performance. In some aspects, the volume percentage or volume fraction of the fibers can be substantially uniform throughout the upper body assembly. In other aspects, the upper body assembly may include multiple regions or segments. The volume percentage of fibers in each region or segment may be the same or different, allowing the volume percentage of fibers to vary throughout the upper body assembly.

[0113] In some aspects, regions comprising a higher volume percentage of fibers may include a quantity of fibers greater than or equal to 40 volume percentage, optionally greater than or equal to 50 volume percentage, or optionally greater than or equal to 60 volume percentage. In some aspects, regions comprising a lower volume percentage of fibers may include a quantity of fibers less than or equal to about 40 volume percentage, optionally less than or equal to about 30 volume percentage, optionally less than or equal to about 20 volume percentage, less than or equal to about 10 volume percentage, or optionally less than or equal to 5 volume percentage. The volume percentage may depend on the strength and / or stiffness characteristics of the fiber material and may be selected to meet the desired strength and / or stiffness characteristics of the superstructure component.

[0114] In some respects, the upper body component may include high-strength regions (or optionally multiple high-strength regions) where high stiffness and / or strength are desired (e.g., due to anticipated loads). High-strength regions may include a higher volume percentage of fibers than other regions.

[0115] In some aspects, the upper body component may include high-transparency areas (or optionally multiple high-transparency areas), where high transparency is desired. Compared to other areas, the high-transparency areas may include a lower volume percentage of fibers.

[0116] Regions with a high volume percentage of fibers (e.g., fibers greater than or equal to about 10% by volume to less than or equal to 40% by volume (or optionally greater than or equal to about 40% by volume)) may have higher tensile strength compared to regions with a low volume percentage of fibers (e.g., fibers less than or equal to about 10% by volume, or optionally no fibers). However, regions with a high volume percentage of fibers may have lower transparency compared to regions with a low volume percentage of fibers. In some aspects, regions with a high volume percentage of fibers may be at least partially transparent. In some aspects, regions with a substantially high volume percentage of fibers may be substantially opaque.

[0117] In various aspects, the strength and transparency of the upper body component can be customized through the selection of polymers and / or fibers. In some aspects, each region may include the same polymer and / or fibers. In some other aspects, each region may include different polymers and / or fibers. In some aspects, regions may include polymers that are substantially fiber-free (e.g., when high transparency is required). The substantially fiber-free polymer may be the same as or different from the polymer in the regions that include both polymers and fibers. Any combination of polymers including any combination of fibers may be used and configured to provide the desired strength and transparency characteristics of the upper body component.

[0118] 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 preimpregnation process) (also known as "continuous unidirectional fibers"). Continuous unidirectional fibers can have high strength in the planar direction. However, continuous unidirectional fibers can have relatively low strength in non-planar directions. In one example, continuous unidirectional fibers can be included in the upper body assembly where the desired strength and / or stiffness is in a substantially planar direction.

[0119] In some respects, the fibers can be discontinuous and oriented in multiple directions (e.g., oriented in random directions) (also known as "discontinuous, in-plane random fibers"). In one instance, discontinuous, in-plane random fibers may be included in the upper body assembly, where the desired strength and / or stiffness is in multiple directions.

[0120] In some respects, the fibers can be discontinuous and oriented in a planar direction (also known as "discontinuous, in-plane oriented fibers"). Fibers oriented in a planar direction may have increased strength in that direction. However, in various aspects, the strength characteristics of the upper body assembly, including discontinuous, in-plane oriented fibers, can be customized by the shape of the fibers.

[0121] In some respects, substantially flat fibers can have an increased surface area compared to substantially cylindrical fibers. This increased surface area can increase the strength of the assembly in a second direction (e.g., increased strength in a direction substantially perpendicular to the fiber orientation direction). Therefore, an upper body assembly comprising substantially flat fibers can have increased strength in more than one direction compared to an upper body assembly comprising substantially cylindrical fibers.

[0122] In various aspects, the shape of the fibers can also be used to customize the transparency of the upper body component. Generally flat fibers can have a surface with lower curvature compared to generally cylindrical fibers. A surface with lower curvature can increase transparency (e.g., the lower curvature of generally flat fibers reduces the amount of optical distortion). Therefore, an upper body component comprising generally flat fibers can have increased transparency compared to an upper body component comprising generally cylindrical fibers. Fiber orientation and shape can be varied and / or combined as needed to provide desired strength and transparency characteristics in different areas of the upper body component.

[0123] In various aspects, the strength and transparency of the upper body component can be customized through the component thickness. In some aspects, in areas requiring higher strength and lower transparency, the upper body component may have an increased thickness, for example, 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 may 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 areas requiring lower strength and higher transparency, the upper body component may have a reduced thickness, for example, 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 may 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 may be varied as needed to provide structural support, strength, and / or transparency in desired areas of the upper main body component.

[0124] In various aspects, the upper body component may include one or more additives to achieve desired properties. In some aspects, certain properties of the polymer of the upper body component may change over time upon exposure to UV light from the sun. In some aspects, the polymer may include additives (e.g., chemical groups) configured to absorb UV light. The polymer may include chromophores. In some aspects, the polymer may include halogenated flame retardants, fillers, pigments, and / or combinations thereof. In some aspects, the polymer may include a variety of additives. Additives may include UV absorbers, quenchers, hindered amine light stabilizers (HALS), or any combination thereof. In some aspects, additives may be added in amounts that substantially do not impede the desired transparency.

[0125] In some aspects, UV absorbers can be configured to dissipate heat through the polymer (e.g., converting UV radiation into infrared radiation). In some aspects, UV absorbers include carbon black, rutile titanium dioxide, benzophenone, hydroxyphenylbenzotriazole, N,N'-oxalyldiphenylamine (e.g., in an upper body assembly including PA), benzophenone (e.g., in an upper body assembly including PVC), benzotriazole (e.g., in an upper body assembly including PC), hydroxyphenyltriazine (e.g., in an upper body assembly including PC), or combinations thereof.

[0126] In some respects, during UV light exposure, the chromophore can gain energy from the UV light and change its energy state from a lower energy ground state to a higher energy excited state. In some respects, the quencher can be configured to return the chromophore from the higher energy excited state to the lower energy ground state. In some respects, the quencher includes the element nickel (Ni).

[0127] In some aspects, HALS can be configured to capture free radicals formed during UV light exposure. HALS may include a 2,2,6,6-tetramethylpiperidine ring structure. In some aspects, additives may include combinations of UV absorbers, quenchers, and / or HALS to achieve desired strength, transparency, and color-changing properties.

[0128] In some respects, the upper body assembly may be formed by compression molding. In other respects, the upper body assembly may be formed by injection molding. In some respects, the molding process may utilize a preformed preimpregnated polymer, a fiber-free preformed polymer (e.g., a dry fiber preform), or both a preformed preimpregnated polymer and a fiber-free preformed polymer.

[0129] refer to Figure 1 The present disclosure provides an upper body structure 100 for a vehicle according to various aspects thereof. The upper body structure 100 may at least partially define the upper edge of a vehicle passenger compartment 102. The upper body structure 100 includes a pair of generally laterally spaced A-pillars 104 and a pair of roof beams 106. The roof beams may include a driver-side roof beam 108 and a passenger-side roof beam 110. The A-pillars 104 may be substantially parallel and may project substantially forward within the vehicle. The roof beams 106 may be fixed to or integrally formed with the respective A-pillars 104. The roof beams 106 may extend substantially rearward along a longitudinal length 112 of the vehicle. Alternative vehicle structures may include additional structural pillars (not shown). The pillars may optionally include a pair of B-pillars, a pair of C-pillars, and an optional pair of D-pillars. The pillars may extend substantially vertically from the roof beams 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.

[0130] The roof 120 may be at least partially disposed between the roof beams 106. The roof 120 may extend substantially laterally across the vehicle's span length 122 and substantially longitudinally across the vehicle's front-to-rear length 112. The roof 120 may be configured to provide structural support, occupant visibility, and protection of occupants from rain, snow, UV light, and other elements.

[0131] A front window brow 130 (also referred to as "window brow 130") may be at least partially disposed between the roof beams 106 and substantially perpendicular to their extension. A rear window brow 132 may be at least partially disposed between the roof beams 106 and substantially perpendicular to their extension. The front window brow 130 may be configured to connect the driver's side roof crossbeam 108 to the passenger side roof beam 110 approximately at the front A-pillar 104. The rear window brow 132 may be configured to connect the roof beams 106 approximately at the rear of the vehicle. The front and rear window brows 130 and 132 may extend across the straddle length 122 of the roof 120. The front window brow 130 may be configured to connect the roof 120 to the windshield 134.

[0132] In some respects, such as Figure 1 As shown, the superstructure 100 does not have cross-bracing reinforcements. In some other respects, the superstructure 100 may optionally further include one or more cross-bracing reinforcements (not shown). The cross-bracing reinforcements may extend substantially orthogonally between the roof beams 106. If necessary, the cross-bracing reinforcements may be longitudinally spaced across a front-rear length 112 to provide structural support and / or strength to the superstructure 100.

[0133] According to various aspects of this disclosure, one or more components of the superstructure 100 may be at least partially transparent (i.e., one or more areas may have greater than 0% transparency). In some aspects, a portion of the superstructure may be substantially opaque. In some aspects, the roof 120 may be at least partially transparent, as described below in the accompanying... Figure 2-4 As described in the discussion. In some respects, the window brow 130 may be at least partially transparent, as described below in the discussion accompanying Figures 5-9. In some respects, both the window brow 130 and the roof 120 may be at least partially transparent.

[0134] Reference Figure 2The roof 120 includes a body 202. The body 202 extends substantially laterally between a first side 204 and a second side 206 (also referred to as "sides 204, 206"). Sides 204, 206 may be configured to connect each roof beam 106. The body 202 extends substantially longitudinally between a front end 208 and a rear end 210 (also referred to as "ends 208, 210"). The front end 208 may be configured to attach to a window lintel 130. In some aspects, the front end 208 may be configured to attach directly to the window lintel 130. The rear end 210 may be configured to attach to a rear window lintel 132. In some aspects, the rear end 210 may be configured to attach directly to the rear window lintel 132.

[0135] In various aspects, the roof according to various aspects of this disclosure may have customized intensity and transparency. In some aspects, the roof may have uniform intensity and transparency. In some other aspects, the roof may include multiple regions or segments with different intensities and transparency. For example, the roof may have a first region and a second region, the first region having a first intensity and a first transparency, and the second region having a second intensity and a second transparency, the second intensity and the second transparency being different from the first intensity and the first transparency. The roof may optionally include more than two regions with varying intensity and transparency, for example, optionally more than or equal to three regions, optionally more than or equal to five regions, optionally more than or equal to ten regions, or optionally more than or equal to fifteen regions. In some aspects, the roof may include one or more gradients of transparency.

[0136] refer to Figure 3 The present disclosure provides a roof 300 of a superstructure according to various aspects thereof, which, apart from the roof 300, can be similar to... Figure 1 The upper main structure 100. In addition to the description below, the roof 300 can be connected with... Figure 1-2 The roof 300 is identical to the roof 120. In some respects, the roof 300 may include a first region 302, a second region 304, a third region 306, and a fourth region 308 (also referred to as "regions 302, 304, 306, 308"). In some respects, the transparency and intensity of each of regions 302, 304, 306, and 308 may be substantially equal.

[0137] In some other respects, the transparency and / or intensity of each of regions 302, 304, 306, and 308 may differ. For example, the first region 302 may have a first transparency greater than or equal to about 10% and less than or equal to about 20% (e.g., about 15%). The second region 304 may have a second transparency greater than or equal to about 40% and less than or equal to about 10% (e.g., about 4%). The third region 306 may have a third transparency greater than or equal to about 20% and less than or equal to about 40% (e.g., about 30%). The fourth region 308 may have a transparency greater than or equal to about 50% and less than or equal to about 70% (e.g., about 60%).

[0138] In some other respects, all or part of regions 302, 304, 306, and 308 may be similar or identical to other regions 302, 304, 306, and 308 of the roof 300 in terms of transparency and / or intensity. In one example, the first and second regions 302 and 304 have the same or similar transparency and / or intensity, and the third and fourth regions 306 and 308 have the same or similar transparency and / or intensity. In some other respects, all or part of the regions may have different geometries (e.g., shape, size, and / or location) and / or arrangements. Any combination of regions, including any combination of intensity and transparency, may be utilized and arranged to provide the desired intensity and transparency characteristics of the upper body assembly.

[0139] Reference Figure 4 The roof 400 is provided according to various aspects of this disclosure. In addition to what is described below, the roof 400 may be... Figure 1-2 The roof 400 is the same as the roof 120. In some aspects, the roof 400 may include a gradient 402. In some aspects, gradient 402 may be an intensity gradient. In some aspects, gradient 402 may be a transparency gradient. In some aspects, gradient 402 may be both an intensity gradient and a transparency gradient. In some aspects, intensity may increase as transparency decreases, and intensity may decrease as transparency increases.

[0140] In some respects, the roof 400 may include more than one gradient (e.g., gradients at different locations and / or in different directions), such as two or more gradients, optionally three or more gradients, optionally four or more gradients, optionally five or more gradients, or optionally ten or more gradients. Additional gradients may have the same or different intensity and / or transparency characteristics.

[0141] In some respects, gradient 402 may include a first gradient 404 extending from the first side 406 to the second side 408 (also referred to as "sides 406, 408"). Figure 4As shown, the first gradient 404 may optionally include a first side gradient 410, which mirrors the second side gradient 412 about the lateral center 411 (also referred to as "center 411") of the roof 400. In some aspects, gradient 402 may optionally include a second gradient 414 extending from the front end 416 to the rear end 418 (also referred to as "ends 416, 418"). The second gradient 414 may optionally include a front gradient 420 and a rear gradient 422, as shown. Figure 4 As shown. In some aspects, gradient 402 may include both the first gradient 404 and the second gradient 414. In some aspects, gradient 402 includes all gradients 410, 412, 420, and 422.

[0142] In some aspects, the center 411 of the roof 400 may have a first intensity and a first transparency. Sides 406 and 408 may have a second intensity higher than the first intensity and a second transparency lower than the first transparency. The second side 408 may have an intensity and transparency substantially equal to that of the first side 406. The gradient 402, including the first side gradient 410 and the second side gradient 412, may have substantially equal rates of change in intensity and transparency from the center 411 to the respective sides 406 and 408. In some other aspects, the first side gradient 410 and the second side gradient 412 may have different rates of change in intensity and transparency from the center 411 to the respective sides 406 and 408.

[0143] In some aspects, the center 411 of the roof 400 may have a third intensity and a third transparency, and the ends 416, 418 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 rear end 418 may have an intensity and transparency substantially equal to that of the front end 416. The gradient 402, including the front gradient 420 and the rear gradient 422, may have substantially equal rates of change in intensity and transparency from the center 411 to the respective ends 416, 418. In some other aspects, the front gradient 420 and the rear gradient 422 may have different rates of change in intensity and transparency from the center 411 to the respective ends 416, 418.

[0144] In some other respects, the roof may have only one of the first gradient 404 and the second gradient 414. In some other respects, the roof may have one or more different gradients in addition to or as an alternative to the first and second gradients 404, 414. The desired intensity and transparency characteristics of the roof 400 can be achieved using gradients of any construction and arrangement.

[0145] Reference Figures 5A-5B The upper main structure is 100 ( Figure 1 The window lintel 130 includes an elongated body 540. The elongated body 540 extends between a first side 542 and a second side 544 (also referred to as "sides 542, 544"). The elongated body 540 may include a front end 546 and a rear end 548 (also referred to as "ends 546, 548"). Sides 542, 544 may be configured to be coupled to the driver's side roof beam 108, respectively. Figure 1 ) and passenger side roof beam 110 ( Figure 1 ).

[0146] Windshield 134 ( Figure 1 The window lintel 130 may have the desired glass curvature (not shown) to conform to the structural design of the vehicle. The window lintel 130 may have a curvature substantially similar to that of the glass. The window lintel 130 may have different geometries (e.g., shape and / or curvature), features (e.g., outer edges and / or construction), and configurations as needed to meet the desired mechanical performance characteristics of the superstructure 100.

[0147] The window brow 130 can be configured to integrate the windshield 134 into the roof 120. In some aspects, such as Figure 5B As shown, the window brow 130 can be directly bonded to the roof 120 using adhesive 552. Adhesive 552 can be a transparent adhesive (e.g., a polyurethane adhesive). In some respects, in addition to or as an alternative to adhesive, the window brow 130 can be directly bonded to the roof 120 using mechanical fasteners (not shown).

[0148] In some respects (not shown), the window brow 130 can be directly integrated into both the windshield 134 and the roof 120. The front end 546 can be configured to be integrated into the windshield 134. The rear end 548 can be configured to be integrated into the roof 120.

[0149] Return to reference Figure 5B In some aspects, the window header 130 may include a first component 554 and a second component 556 (also referred to as "components 554, 556"). Components 554, 556 may be formed individually (e.g., molded). Components 554, 556 may be joined together with each other. In some aspects, components 554, 556 are directly joined together by an adhesive (e.g., a transparent polyurethane adhesive) and / or welding. In some aspects, the window header 130 may include more than two components, such as three or more components, optionally four or more components, or optionally five or more components. In some other aspects, the window header 130 may be a single-piece integral component.

[0150] As described above, the headers according to various aspects of this disclosure can have customized intensity and transparency. In some aspects, the header can have uniform intensity and transparency. In some other aspects, the header can include multiple regions or segments with different intensities and transparency. For example, the header can have a first region and a second region, the first region having a first intensity and a first transparency, and the second region having a second intensity and a second transparency, the second intensity and the second transparency being different from the first intensity and the first transparency. In some aspects, the header can include more than two regions with varying intensities and / or transparency, such as three or more regions, optionally five or more regions, optionally ten or more regions, or optionally fifteen or more regions. In some aspects, the header can include gradients or multiple gradients of transparency and / or intensity.

[0151] refer to Figures 6A-6B The disclosure provides a lintel 600 for the upper main structure according to various aspects thereof, which (except for the lintel 600) may be similar to Figure 1 The upper main structure 100. In addition to the description below, the window lintel 600 can be connected with... Figure 1 and Figures 5A-5B The brow 130 is the same. The brow 600 may include a first region 602. The brow 600 may include one or more sub-regions, such as a first outer region 604 and a second outer region 606 (also referred to as "outer regions 604, 606"). The first region 602 may extend from a first side 608 to a second side 610. The outer regions 602 and 604 may include the first side 608 and the second side 610, respectively. The outer regions 602 and 604 may include a front end 612 and a rear end 614.

[0152] In some respects, such as Figure 6B As best shown, the first region 602 includes a polymer 616 and a plurality of fibers 618 (e.g., high-strength fibers such as continuous fibers). As an example, the plurality of fibers 618 (also referred to as “first fibers 618”) may be included in a volume percentage greater than or equal to about 10%. The first fibers 618 may be partially positioned around the edge 620 of the brow 600 (e.g., by tape). In some respects, the first fibers 618 may be partially positioned toward the front end 612 and the rear end 614. The first fibers 618 may be formed in a plurality of tow lines 626 extending between the first side 608 and the second side 610. The placement of the first fibers 618 on the edge 620 and / or the tow lines 626 may form a substantially fiber-free interior region 628.

[0153] The outer regions 604, 606 may include a polymer 616, a first plurality of first fibers 618, and a second plurality of fibers 630 (also referred to as "second fibers 630"). In some aspects, the second fibers 630 may be present in the outer regions 604, 606 at a volume percentage higher than that of the first fibers 618 in the first region 602. In some aspects, the outer regions 604, 606 include a second polymer different from the polymer 616. The second polymer may optionally be opaque.

[0154] In some respects, the first fiber 618 of the first region 602 may be discontinuous. The second fiber 630 of the outer regions 604 and 606 may be continuous. The discontinuous fiber may be randomly oriented, planar oriented, or both. The continuous fiber may be planar oriented. In some respects, the first fiber 618 may be continuous along the edge of the first region 602. The first fiber 618 and the second fiber 630 may have the same or different orientations to meet desired performance characteristics.

[0155] In some respects, the brow 600 may have a higher strength in the outer regions 604, 606 than the rest of the brow 600. At least a portion of the first region 602 may have a lower strength compared to the outer regions 604, 606.

[0156] In some respects, the brow 600 may have the highest transparency in the essentially fiber-free inner region 628. The outer regions 604, 606 may have lower transparency compared to the inner region 628. In some respects, the trailing line 626 in the first region 602 may be substantially opaque because the first fiber 618 is partially placed on the edge 620.

[0157] refer to Figures 7A-7B The disclosure provides a lintel 700 for the upper main structure according to various aspects thereof, which (except for the lintel 700) may be similar to Figure 1 The upper main structure 100. In addition to the description below, the window lintel 700 can be connected with... Figure 1 and Figures 5A-5B The brow 130 is the same. The brow 700 may include a first outer region 702, a second outer region 704 (also referred to as "outer regions 702, 704"), and an inner region 706. The first outer region 702 may include a first side 708. The second outer region 704 may include a second side 710. The inner region 706 may be at least partially disposed between the first outer region 702 and the second outer region 704.

[0158] In some respects, such as Figure 7BAs best shown, outer regions 702, 704 and inner region 706 may include polymer 720 and a plurality of fibers 722. The fibers 722 of inner region 706 may be locally formed around the edge 724 of the brow 700. Inner region 706 may have a substantially fiber-free local region 726. Local region 726 may extend co-exist with inner region 706. In some aspects, outer regions 702, 704 may include a higher volume percentage of fibers 722 compared to inner region 706. The volume percentage of fibers 722 in first outer region 702 may be substantially equal to the volume percentage of fibers 722 in second outer region 704.

[0159] The outer regions 702 and 704 may have a first intensity and a first transparency. The inner region 706 may have a second intensity and a second transparency. The second intensity of the inner region 706 may be less than the first intensity of the outer regions 702 and 704. The inner region 706 may have a higher transparency than the outer regions 702 and 704.

[0160] refer to Figures 8A-8B The disclosure provides a lintel 800 for the upper main structure according to various aspects thereof, which (except for the lintel 800) may be similar to Figure 1 The upper main structure 100. In addition to the description below, the window lintel 800 can be connected with... Figures 7A-7B The same as the header 700. The header 800 may include a first outer region 802, a second outer region 804 (also referred to as "outer regions 802, 804") and an inner region 806.

[0161] In some respects, such as Figure 8B As best shown, outer regions 802 and 804 may be composed of a first polymer 820 and a first plurality of fibers 822. In some respects, the volume percentage of fibers 822 in the first outer region 802 is substantially equal to the volume percentage of fibers 822 in the second outer region 804. The inner region 806 may be composed of a fiber-free second polymer 830. The second polymer 830 may be the same as or different from the first polymer 820.

[0162] The outer regions 802 and 804 may have a higher intensity than the inner region 806. In some aspects, the outer regions 802 and 804 may be at least partially transparent, while the inner region 806 may have a higher transparency than the outer regions 802 and 804. In some aspects, the outer regions 802 and 804 may be substantially opaque. In some aspects, the substantially fiber-free inner region 806 may be substantially transparent.

[0163] Reference Figure 9 The window header 900 is provided according to various aspects of this disclosure. In addition to what is described below, the window header 900 may be used with... Figure 1 and Figures 5A-5B The header 900 is the same as 130. In some aspects, the header 900 may include a gradient 902. In some aspects, gradient 902 may be an intensity gradient. In some aspects, gradient 902 may be an opacity gradient. In some aspects, gradient 902 may be both an intensity gradient and an opacity gradient. In some aspects, intensity may increase as opacity decreases, and intensity may decrease as opacity increases.

[0164] In some respects, the brow 900 may include more than one gradient (e.g., gradients at different locations and / or in different directions), such as two or more gradients, optionally three or more gradients, optionally four or more gradients, optionally five or more gradients, or optionally ten or more gradients. Additional gradients may have the same or different intensity and / or transparency characteristics.

[0165] In some aspects, gradient 902 may include a first gradient 904 extending from the first side 906 to the second side 908 (also referred to as "sides 906, 908"). Figure 9 As shown, the first gradient 904 may optionally include a first side gradient 910 mirrored about the lateral center 911 (also referred to as "center 911") of the brow 900 to the second side gradient 912. In some aspects, gradient 902 may optionally include a second gradient 914 extending from the front end 916 to the rear end 918 (also referred to as "ends 916, 918"). The second gradient 914 may optionally include a front gradient 920 and a rear gradient 922, as shown. Figure 9 As shown. In some aspects, gradient 902 may include a first gradient 904 and a second gradient 914. In some aspects, gradient 902 includes all gradients 910, 912, 920, and 922.

[0166] In some aspects, the center 911 of the brow 900 may have a first intensity and a first transparency. Sides 906 and 908 may have a second intensity higher than the first intensity and a second transparency lower than the first transparency. The second side 908 may have an intensity and transparency substantially equal to that of the first side 906. The gradient 902, including the first side gradient 910 and the second side gradient 912, may have substantially equal rates of change in intensity and transparency from the center 911 to the respective sides 906 and 908. In some other aspects, the first side gradient 910 and the second side gradient 912 may have different rates of change in intensity and transparency from the center 911 to the respective sides 906 and 908.

[0167] In some aspects, the center 911 of the brow 900 may have a third intensity and a third transparency, and the ends 916, 918 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 rear end 918 may have an intensity and transparency substantially equal to that of the front end 916. The gradient 902, including the front gradient 920 and the rear gradient 922, may have substantially equal rates of change in intensity and transparency from the center 911 to the respective ends 916, 918. In some other aspects, the front gradient 920 and the rear gradient 922 may have different rates of change in intensity and transparency from the center 911 to the respective ends 916, 918.

[0168] In some other aspects, the brow may have only one of the first gradient 904 and the second gradient 914. In some other aspects, the brow may have one or more different gradients other than or alternative to the first gradient 904 and the second gradient 914. The desired intensity and transparency characteristics of the brow 900 can be achieved using any gradient configuration and arrangement.

[0169] For illustrative and descriptive purposes, the above description of the embodiments has been provided. It is not intended to be exhaustive or limiting of this disclosure. Various elements or features of a particular embodiment are generally not limited to that particular embodiment, but are interchangeable where applicable and can be used in selected embodiments, even if not specifically shown or described. The same can also be varied in many ways. Such variations should not be considered as departing from this disclosure, and all such modifications are intended to be included within the scope of this disclosure.

Claims

1. A roof for the upper main structure of a vehicle, comprising: The body extends between a first side and a second side and between a front end and a rear end, the body comprising, Polymers and multiple fibers, The front end is configured to be integrated into the header, wherein at least a portion of the main body has a transparency of 4% or greater. The main body includes, A first region having first transparency and first tensile strength, and A second region having a second transparency and a second tensile strength, wherein the second transparency is greater than the first transparency and the second tensile strength is less than the first tensile strength. in: The first region comprises a first volume percentage of fibers. The second region includes a second volume percentage of fibers, and The first volume percentage of the fiber is greater than the second volume percentage of the fiber.

2. The roof according to claim 1, wherein the transparency is greater than or equal to 50% and less than or equal to 99%.

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

4. The roof according to claim 1, wherein the local tensile strength of the main body is greater than or equal to 40 MPa and less than or equal to 1000 MPa.

5. The roof according to claim 1, wherein at least a portion of the main body is free of fibers.

6. The roof according to claim 1, wherein the plurality of fibers are substantially uniformly distributed throughout the body.

7. The vehicle roof according to claim 1, wherein: The first region defines the first thickness. The second region defines the second thickness, and The first thickness is greater than the second thickness.

8. The roof according to claim 1, wherein the body further comprises a third region having a third transparency and a third tensile strength.

9. The roof of claim 1, wherein the body further comprises a fourth region having a fourth transparency and a fourth tensile strength.

10. The roof of claim 1, wherein the main body defines a transparency gradient.

11. The roof of claim 10, wherein the transparency gradient comprises a plurality of transparency gradients.

12. The roof of claim 11, wherein the plurality of transparency gradients include a first gradient and a second gradient, the second gradient having a rate of change substantially equal to that of the first gradient.

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

14. The roof according to claim 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.

15. The roof according to claim 14, wherein: The plurality of fibers have shapes selected from: cylindrical, flat, or both cylindrical and flat, and The fibers have an orientation selected from the following: continuous in a first planar direction, discontinuous in a first planar direction, discontinuous in multiple directions, or any combination thereof.

16. The roof according to claim 1, wherein the plurality of fibers comprises a plurality of continuous fibers and a plurality of discontinuous fibers.

17. The roof according to claim 1, wherein the main body further comprises an additive selected from: ultraviolet absorbers, quenchers, hindered amine light stabilizers, or combinations thereof.

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