Guide plate and method for manufacturing guide element of guide plate made of warp knitted fabric

Abstract

The invention relates to a wind deflector for an openable vehicle roof with a movable covering element (16), the wind deflector comprising a deployable wind deflector element (26) made of a flat flexible material and forming a windward surface (30), the wind deflector element (26) being attached at its upper edge region to a pivotable deployment bow (20) and at its lower edge region to a vehicle attachment base (28), the wind deflector element comprising a warp knitted fabric with a mesh. The warp knitted fabric is formed in one piece, the windward surface (30) being a curved surface, the curvature of which is defined by the interwoven mesh of the warp knitted fabric.

Description

Technical Field

[0001] The invention relates to a wind deflector for an openable vehicle roof and a method for producing a wind deflector element of the wind deflector. Background Art

[0002] This type of wind deflector is known in practice and is used in conjunction with openable vehicle roofs that have a cover element that is movable in the longitudinal direction of the vehicle. The wind deflector is arranged in the front edge region of the roof opening of the vehicle roof, which can be closed or at least partially opened as required by the cover element. The wind deflector comprises a wind-facing element made of a flat, flexible material and attached at its upper edge to a pivotable deployment bow and at its lower edge to a vehicle attachment base. The wind deflector is typically made of a mesh material, which may be a warp-knit fabric. The deployment bow is essentially U-shaped and pivotally mounted at its free legs in the region of a corresponding roof attachment rail, with each free leg forming a deployment arm. Depending on the open position of the cover element, the deployment bow can pivot between a rest position, in which the deflector element is folded and lowered, and a deployed, functional position, in which the deflector element is deployed and forms the wind-facing surface. The deflector is connected to the deployment bow and the vehicle attachment base by a so-called edge band, which forms a welt and is sewn to the flat, flexible material. Alternatively, it is known that the edge band is molded onto the flexible material by injection molding or similar techniques.

[0003] When producing conventional induction mesh, a length of fabric, perhaps a warp-knit fabric, is unwound from a roll. It is then cut using heat or laser cutting. Edge bands are then attached to the resulting cut fabric pieces. The exposed sides of the cut fabric pieces can be protected from tearing by hemming or the like. It is also known to attach reinforcing strips to the cut fabric pieces by molding, gluing, or sewing.

[0004] Cutting fabric to length results in fabric waste. Furthermore, cutting a stack of multiple layers of fabric can cause warping, meaning the resulting fabric cut piece may not meet the required dimensions. Attaching edge welts and reinforcements and forming edge protection is time-consuming and therefore costly. Furthermore, since the fabric cut piece is a two-dimensional, planar element, it can wrinkle when unfolded. Summary of the Invention

[0005] The object of the present invention is to provide a flow guide plate having a flow guide element which can be produced in a cost-effective production process, and a method for producing such a flow guide element.

[0006] According to the invention, this object is achieved by a deflector and a method having the features of the present application.

[0007] Therefore, according to the present invention, a wind deflector for an openable vehicle roof with a movable cover element is proposed, the wind deflector comprising a deployable deflector element made of a flat, flexible material and forming a windward surface, the deflector element being attached at its upper edge region to a pivotable deployment bow and at its lower edge region to a vehicle attachment base, the deflector element being a one-piece warp-knitted fabric having or formed from a mesh. The windward surface of the deflector element is a curved surface, the curvature of which is defined by the interwoven mesh of the warp-knitted fabric.

[0008] The present invention thus provides a deflector element for a wind deflector, the deflector element being a three-dimensional warp-knitted component, the width, height, and depth of which, as well as its curvature, are generated by the warp-knitting process itself. Consequently, solely due to its manufacturing process, the deflector element preferably has a three-dimensional profile that corresponds to the profile of the deflector element when deployed in the deployed state of the pivotable deployment bow. The deflector element is preferably wrinkle-free in its deployed state, as its windward surface is curved.

[0009] In a preferred embodiment of the deflector, the warp-knitted fabric features a warp-knitted edge thickening. This warp-knitted edge thickening can be used directly to attach the deflector element to the deployment bow or to the vehicle attachment base, thus serving as a welt or side protection to protect the warp-knitted fabric from tearing. The warp-knitted edge thickening is co-produced directly during the warp-knitted fabric production process. This eliminates the need for subsequent processing, which in turn reduces the production costs of the deflector element.

[0010] In another embodiment of the deflector according to the present invention, the warp knitted fabric of the deflector element has a warp knitted pocket, in which the reinforcing element is arranged. During the production process of the warp knitted fabric of this embodiment, the pocket is also produced simultaneously.

[0011] In a preferred embodiment of the wind deflector according to the invention, the pockets of the warp-knitted fabric are edge pockets which accommodate welt elements as reinforcement elements, which connect the wind deflector element to the deployment bow or the vehicle attachment base.

[0012] Alternatively, the pocket can also be formed in the surface of the flow-guiding element and spaced apart from the edge, so that the reinforcement element supports the shaping of the flow-guiding element in the unfolded state of the flow-guiding element.

[0013] The reinforcing elements, which may be in the form of tapes, cords or strips, may be completely sheathed by the warp-knitted fabric, which means that the reinforcing elements are incorporated directly in the form of inserts during the production of the warp-knitted fabric.

[0014] Alternatively, the reinforcing element can also be inserted into the pocket. In this case, the pocket preferably has an opening through which the reinforcing element can be introduced.

[0015] In a further preferred embodiment of the wind deflector according to the invention, the coupling pocket can have recesses, which means that the reinforcing elements, in particular the welt elements, are exposed in the region of these recesses.

[0016] In order to secure the reinforcing element in the pocket in question, the warp-knitted fabric can be configured in the pocket region such that the reinforcing element is hooked by the warp-knitted fabric from behind and cannot slip out of the pocket.

[0017] In another special embodiment of the deflector according to the invention, the warp-knitted fabric has a warp-knitted reinforcement region at a distance from its edge. The reinforcement region is preferably formed directly from the yarns of the warp-knitted fabric.

[0018] Another special embodiment of the deflector according to the invention is configured such that the warp knitted fabric has sections of different material thicknesses, so that for example optically visible warp knitted stripes can be formed, which can extend vertically or horizontally.

[0019] Furthermore, it is conceivable that the warp-knitted fabric is provided with a pattern, which means, for example, that the warp-knitted fabric logo of the vehicle manufacturer is formed.

[0020] In addition, the warp-knitted fabric can have attachable tabs in its side edge regions. The tabs can be warp-knitted or attached in addition, which, for example, all have buttonhole-shaped holes.

[0021] In the method according to the invention for producing a planar flexible air guiding element, the thread system is warp-knitted by means of a warp-knitting machine in such a way that the resulting meshes together define an at least partially curved surface forming the windward surface of the air guiding element.

[0022] In this method, at least one edge thickening is preferably warp-knitted into the warp-knitted fabric, which edge thickening serves to attach the deflector element to a deployment bow or a vehicle attachment base or to form lateral edge protection. Therefore, any thread system introduced into the warp-knitting machine also generates the edge thickening in the warp-knitting machine.

[0023] In a particular embodiment according to the invention, at least one pocket for accommodating a reinforcing element is also warp-knitted from the thread system to the warp-knitted fabric, the pocket being an edge pocket for accommodating a welt element or a pocket in the surface of the guide element for accommodating a shaped reinforcing element.

[0024] The reinforcement elements can be warp-knitted directly into the warp-knitted fabric during the process or inserted into the pockets after the warp-knitted fabric has been produced.

[0025] The method according to the invention saves costs compared to known production methods because no waste is generated. The width, height, and curvature of the deflector element can be easily adjusted on the warp knitting machine. No expensive steps are required for attaching welts and / or reinforcement elements and / or edge protectors. Furthermore, the deflector element according to the invention forms a dimensionally stable and accurately formed part.

[0026] Further advantages and advantageous embodiments of the subject matter of the invention are apparent from the description, the drawings and the claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Illustrative examples of deflectors according to the invention are schematically shown in the accompanying drawings and will be discussed in more detail in the following description.

[0028] Figure 1 is a perspective top view of the top of the vehicle including the deflector;

[0029] Figure 2 It is a three-dimensional diagram of the deflector;

[0030] Figure 3 shows half of a deflector element of a deflector plate; and

[0031] Figure 4 It is along Figure 3 The IV-IV line in FIG. 1 passes through the cross-sectional view of the flow guide element. DETAILED DESCRIPTION

[0032] The figures show a motor vehicle 10 having a vehicle roof 12 provided with a roof opening 14 which can be closed or at least partially opened as required by a movable cover element 16 .

[0033] The deflector 18 can be deployed according to the opening degree of the cover element 16 and is provided adjacent to the front edge area of ​​the top opening 14. The deflector 18 extends substantially in the transverse direction of the vehicle and is used to prevent potential air flow disturbance and air turbulence from occurring inside the vehicle when the top opening 14 is opened. Figures 2 to 4 The deflector 18 described in detail is a functional element that comes into play when the cover element 16 is in the open position.

[0034] The deflector 18 includes an at least approximately U-shaped deployment bow 20 with two legs 22A and 22B serving as deployment arms, and a transverse leg 24 extending in the vehicle's transverse direction and connecting the two legs 22A and 22B, which extend in the vehicle's longitudinal direction. The deployment arms 22A and 22B are each pivotally mounted in the area of ​​a guide rail for the cover element 16, which extends in the vehicle's longitudinal direction, and are preloaded in the deployment direction by a deployment spring. The degree of deployment of the deployment arms 22A and 22B, and therefore the deployment bow 20, is determined by the position of the cover element 16 in the vehicle's longitudinal direction. When the top opening 14 is closed, the cover element 16, starting from its open position, slides rearward onto the deployment arms 22A and 22B, pushing them downward against the force of the deployment springs and pivoting the deployment bow 20 from its functional position to its rest position. When the cover element 16 moves rearward, the deployment arms 22A and 22B are released, allowing the deployment bow 20 to automatically move to its functional position under the action of the deployment springs.

[0035] The guide plate 18 includes a guide element 26, which is Figure 3 and Figure 4 1 and is arranged between the deployment bow 20 and a vehicle attachment base 28 , which can be formed by a sunroof frame and comprises guide rails for the cover element 16 .

[0036] The deflector element 26 is made of a flexible, foldable material and is a warp-knitted three-dimensional shaped piece. It integrally forms the windward surface 30 of the deflector 18. The windward surface 30 is a curved surface whose curvature is defined by the interwoven mesh of the warp-knitted fabric. The contour and curvature of the shaped piece, i.e., the warp-knitted fabric, are predetermined by the warp-knitting process performed in the warp-knitting machine.

[0037] The warp-knitted flow-guiding element 26 comprises, at its upper edge and at its lower edge, respective warp-knitted edge thickenings 32, each edge thickening 32 being formed by a pocket 34 housing a strip-shaped welt element 36 for forming an edge welt, the welt element 36 being a reinforcing element and extending across the entire width of the flow-guiding element 26. In the installed position, the edge welt formed by the pocket 34 and the welt element 36 engages a respective welt groove of the deployment bow 20 and of the vehicle attachment base 28.

[0038] The warp-knit fabric has warp-knitted edge thickenings 38 at the side edges of the flow guide element 26 , which are formed by thickening the material, in order to provide edge protection for these edges.

[0039] In order to stabilize the windward surface 30 of the laterally curved surface sections, the deflector element 26 has two reinforcing ribs 40 in each of its lateral sections on both sides, each of which is also formed by a corresponding warp-knitted pocket 42, each of which is provided with a reinforcing element 44 in the form of a plastic strip, belt or thread. The pockets 42 are also produced during the production of the deflector element 26.

[0040] The deflector element 26 is produced by means of a warp knitting machine using a warp knitting thread system, such that the resulting meshes together define the curved windward surface 30, and the pockets 34 and 42 as well as the edge thickening 38 are warp knitted jointly from the thread system during the production process. During the warp knitting process, the welt elements 36 for forming the edge welts and the reinforcing elements 44 for forming the ribs 40 are surrounded by the thread system used, so that the finished deflector element 26, including the elements 36 and 44 knitted therein, can be removed from the warp knitting machine and can be connected to the vehicle attachment base 28 and the deployment bow 20 of the deflector 18 during the assembly process without any additional prior processing.

[0041] Reference Signs List

[0042] 10 Motor Vehicles

[0043] 12. Top of vehicle

[0044] 14 Top opening

[0045] 16 Cover element

[0046] 18 deflector

[0047] 20 Unfold the Bow

[0048] 22A, 22B legs

[0049] 24 lateral outriggers

[0050] 26 flow guide element

[0051] 28 Vehicle Attachment Base

[0052] 30 Windward surface

[0053] 32 Edge thickening

[0054] 34 pockets

[0055] 36 Edge components

[0056] 38 Edge thickening

[0057] 40 ribs

[0058] 42 pockets

[0059] 44 Reinforcement elements

Claims

1. A wind deflector for an openable vehicle roof with a movable covering element (16), comprising a deployable deflector element (26) made of a flat, flexible material and forming a windward surface (30), the deflector element (26) being attached in its upper edge region to a pivotable deployment bow (20) and in its lower edge region to a vehicle attachment base (28), the deflector element comprising a warp-knitted fabric with a mesh, characterized in that The warp knitted fabric is integrally formed, the windward surface (30) is a curved surface, the curvature of which is defined by the interwoven meshes of the warp knitted fabric, and the integral warp knitted fabric has warp knitted edge thickening portions (32, 38).

2. The guide plate according to claim 1, characterized in that: The edge thickening is a lateral edge protection.

3. The guide plate according to claim 1, characterized in that: The edge thickening includes a welt for attaching the warp knit fabric to the deployment bow (20) or to a vehicle attachment base (28).

4. The guide plate according to any one of claims 1 to 3, characterized in that: The one-piece warp knitted fabric has warp knitted pockets (34, 42) in which reinforcement elements (44) are arranged.

5. The guide plate according to claim 4, characterized in that: The pocket is an edge pocket and the reinforcement element is a welt element (36).

6. The guide plate according to claim 4, characterized in that: The reinforcing element (44) is completely covered by the warp-knitted fabric.

7. The guide plate according to claim 4, characterized in that: The reinforcement element is inserted into the pocket.

8. The guide plate according to claim 4, characterized in that: The pocket has at least one recess, the reinforcing element being exposed in the region of the recess.

9. The guide plate according to any one of claims 1-3 and 5-8, characterized in that: The warp knitted fabric has a warp knitted reinforcement area spaced apart from its edge.

10. The guide plate according to any one of claims 1-3 and 5-8, characterized in that: The warp knitted fabric has sections with different material thicknesses.

11. The guide plate according to any one of claims 1-3 and 5-8, characterized in that: The warp knitted fabric is provided with a warp knitting pattern.

12. The guide plate according to any one of claims 1-3 and 5-8, characterized in that: The warp knitted fabric is provided with side panels.

13. A method for manufacturing a planar flexible deflector element (26) for a deflector (18), the deflector element being made of a warp-knitted fabric with a mesh, the thread system being warp-knitted into a one-piece warp-knitted fabric by means of a warp-knitting machine, so that the resulting mesh together defines an at least partially curved surface forming a windward surface (30) of the deflector element (26), and at least one edge thickening being warp-knitted into the warp-knitted fabric.

14. The method according to claim 13, characterized in that At least one pocket (34, 42) for receiving a reinforcing element (44) is warp-knitted in the warp-knitted fabric.

15. The method according to claim 14, characterized in that The pocket is an edge pocket and the reinforcement element is a welt element (36).

16. The method according to claim 14 or 15, characterized in that The reinforcing element (44) is warp-knitted into the warp-knitted fabric.

17. The method according to claim 14 or 15, characterized in that The reinforcement element is inserted into the pocket.

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